Display Stack Adhesive Layering for Delamination Prevention
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Solution Overview
Problem
Existing electronic devices face challenges in achieving a thinner, lighter, and cheaper design for electronic displays while maintaining durability and optimal user experience, particularly in preventing delamination of display stack layers and ensuring effective light management.
Innovation Solution
The implementation of a display stack structure that includes a coverglass with an antiglare layer, a touch layer, and a black mask, combined with a front light component featuring a lightguide and optimized OCA layers, along with a foam layer to reduce interfacial stresses and enhance adhesion, and a frame that attaches to the display stack to provide structural support and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple display stack layers are bonded using conventional methods, then the device achieves basic structural integrity, but delamination occurs under thermal stress and mechanical pressure
Solution Approach 1:
The patent changes the chemical and physical parameters of the adhesive layers by using silane-based adhesives that undergo condensation polymerization. This chemical transformation creates strong covalent bonds (Si-O-Si) between layers, fundamentally improving bonding reliability and preventing delamination under thermal and mechanical stress.
Solution Approach 2:
The patent employs composite material strategies by combining silane-based adhesives with specific refractive index matching between OCA layers and display components. This composite approach creates a multi-functional adhesive system that provides both mechanical bonding and optical performance, enhancing overall layer stability.
2Strength
If the display stack uses thicker components for durability, then structural strength improves, but device thickness and weight increase
Solution Approach 1:
The patent utilizes thin film adhesives with high bonding strength that can maintain structural integrity at reduced thicknesses. The silane-based adhesive layers are applied as thin films that provide sufficient mechanical strength and delamination resistance without requiring thick component layers, enabling thinner overall device design.
Solution Approach 2:
The patent changes the material properties of adhesive layers to achieve higher bond strength per unit thickness. By using silane-based adhesives with enhanced mechanical properties and optimizing their thickness parameters, the system achieves durable bonding in thinner configurations, reducing overall device thickness while maintaining structural strength.
3Ease of manufacture
If conventional adhesives are used to bond display layers, then manufacturing is simpler, but interfacial stresses cause delamination and reduced light uniformity
Solution Approach 1:
The patent changes the chemical composition and rheological parameters of adhesives to optimize both manufacturing and performance. The silane-based adhesives are formulated with specific viscosity ranges and curing characteristics that facilitate application while providing superior bonding. The refractive index parameters are also optimized to ensure light uniformity across the display interface.
Solution Approach 2:
The patent introduces silane-based adhesive layers as intermediary materials between display stack components. These intermediary layers serve dual functions: providing mechanical bonding to prevent delamination and ensuring optical continuity through refractive index matching. The adhesives act as mediators that reconcile the mechanical and optical requirements of adjacent layers.
4Reliability
If multiple OCA layers are used for optimal bonding, then adhesion improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the functions of multiple OCA layers into a single optimized adhesive layer. By combining bonding, optical matching, and stress distribution functions into one silane-based adhesive system, the patent reduces the number of discrete layers while maintaining or improving adhesion strength. This consolidation simplifies manufacturing processes and reduces assembly 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
This configuration results in a more durable, lightweight, and cost-effective electronic device with improved light uniformity and reduced delamination risks, enhancing user experience and manufacturing efficiency.
Implementation Method 1
a foam layer to reduce interfacial stresses and enhance adhesion
Implementation Method 2
a coverglass with an antiglare layer
Implementation Method 3
optimized OCA layers
Data Source
AI summary
Described herein are electronic devices that includes a display stack having a cover component atop a lightguide component and a display component below the lightguide component. In some instances, the cover component including an antiglare etching applied to a top surface of a coverglass and a touch pattern applied to a bottom surface of the coverglass. In some cases, an optically clear adhesive layer formed from two types of optically clear adhesive may be located between the cover component and the lightguide component and a ring adhesive may be applied to around an outer edge of the cover component, the optically clear adhesive and the lightguide component.