Display Module Bending Protection With Dual-Modulus Cured Layers
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Solution Overview
Problem
Display devices are prone to cracking and damage due to repeated bending or tensile forces during manufacturing or use, particularly in the bending portion where driving elements are mounted.
Innovation Solution
A display module design with a base layer comprising a first portion, a second portion connected to a circuit board, and a flexible third portion, protected by a first protective layer with a modulus of 10^6 Pa or higher, and a second protective layer with a higher modulus, formed through a two-step curing process using different reactants to enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the base layer is made flexible to allow bending, then the adaptability is improved, but the strength and reliability deteriorate due to cracking and damage from repeated bending or tensile forces
Solution Approach 1:
The patent applies local quality by providing protective layers with specific modulus values at the bending portion (third portion) of the base layer, while other portions may have different structural characteristics. The first protective layer with modulus ≥10^6 Pa and second protective layer with higher modulus are specifically positioned at the bending region to provide localized reinforcement where stress concentration occurs during bending operations.
Solution Approach 2:
The patent employs composite materials by combining the flexible base layer with protective layers of appropriate modulus values. The first protective layer (modulus ≥10^6 Pa) and second protective layer (higher modulus) create a composite structure that maintains the overall flexibility of the base layer while providing enhanced strength and crack resistance at the bending portion through the synergistic combination of materials with different mechanical properties.
2Strength
If protective layers with high modulus are applied to the bending portion, then the strength is improved, but the device complexity increases due to multiple layers and curing processes
Solution Approach 1:
The patent applies segmentation by dividing the protective structure into multiple functional layers: a first protective layer with modulus ≥10^6 Pa and a second protective layer with higher modulus. This segmented approach allows each layer to perform its specific function optimally - the first layer provides baseline protection and flexibility, while the second layer enhances strength - thereby achieving high strength without requiring a single overly complex protective structure.
Solution Approach 2:
The patent utilizes parameter changes by carefully controlling the modulus values of different protective layers. The first protective layer has modulus ≥10^6 Pa, while the second protective layer has an even higher modulus. This parameter differentiation allows the structure to achieve high overall strength while maintaining appropriate flexibility through the lower-modulus first layer, resolving the contradiction between strength and complexity.
3Ease of manufacture
If a single curing method is used for the resin composition, then the manufacturing process is simplified, but the manufacturing precision deteriorates due to incomplete curing or defects
Solution Approach 1:
The patent applies segmentation to the curing process by implementing a two-stage curing approach: first curing the resin composition to form the initial protective structure, then second curing to achieve complete curing and defect elimination. This segmented curing process ensures manufacturing precision by allowing each stage to address specific curing requirements, preventing incomplete curing or defects that would occur with a single rushed curing step.
Solution Approach 2:
The patent employs preliminary action by performing the first curing of the resin composition before final assembly and testing. This preliminary curing establishes the basic protective structure and prevents defects early in the manufacturing process, while the subsequent second curing completes the curing to achieve full strength and reliability, thereby ensuring manufacturing precision without excessive complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design significantly enhances the durability and strength of the bending portion, preventing defects during manufacturing and reducing the risk of cracking under bending stress.
Implementation Method 1
curing the resin composition by a first method to form a first cured product
Implementation Method 2
curing the first cured product by a second method different from the first method to form a second cured product
Data Source
AI summary
A display module includes a base layer including a first portion including a light emitting device, a second portion including a circuit board electrically connected to the second portion, and a third portion disposed between the first portion and the second portion, the third portion being bent, a light emitting device layer overlapping the first portion in a plan view and disposed on an upper surface of the first portion of the base layer, a protective film disposed on a lower surface of the base layer, the protective film including an opening overlapping the third portion of the base layer in a plan view, and a first protective layer disposed on a lower surface of the third portion and overlapping the opening of the protective film in a plan view, wherein a modulus of the first protective layer is about 106 Pa or higher than about 106 Pa.