Display Substrate Structure for Reduced Dead Space and Easier Bending
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Solution Overview
Problem
The challenge in display device manufacturing is the presence of significant dead space and non-display areas, which hinder aesthetic appeal and immersion, particularly in devices with reduced non-display areas.
Innovation Solution
A display device design featuring a first substrate made of hard material and a second substrate made of soft material, with specific structural elements like sub-substrates and inclined surfaces, allowing for minimal dead space by optimizing the bending area and substrate thickness, and a manufacturing method involving etching and laser irradiation to form these structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the non-display area width is reduced to increase immersion and enhance aesthetics, then the aesthetic appeal and immersion are improved, but the structural integrity and ease of manufacturing are worsened
Solution Approach 1:
The first substrate is divided into two distinct portions: a first sub-substrate with a first length and a second sub-substrate with a second length. This segmentation allows each portion to be optimized independently - the first sub-substrate provides structural support while the second sub-substrate accommodates the bending area, thus enabling reduced non-display area width while maintaining manufacturing feasibility
Solution Approach 2:
Different regions of the first substrate are assigned different functional qualities - the first sub-substrate region is designed for structural integrity and component mounting, while the second sub-substrate region is designed for flexibility and bending. This local differentiation enables the overall structure to achieve both aesthetic goals (reduced non-display area) and manufacturing requirements
2Ease of operation
If the substrate thickness is reduced to enable easier bending, then the ease of bending is improved, but the strength and damage resistance are worsened
Solution Approach 1:
The first substrate is segmented into first and second sub-substrates with different length proportions. The second sub-substrate, being shorter (first length to second length ratio between 1:50 and 1:200), is positioned to accommodate the bending area, enabling easier bending. The first sub-substrate maintains adequate thickness and structural support, thus resolving the contradiction between bending ease and strength
Solution Approach 2:
The patent specifies precise parameter ranges - the first substrate thickness is controlled within 0.1mm to 0.5mm, and the first length to second length ratio is maintained between 1:50 and 1:200. These parameter optimizations enable the substrate to achieve both sufficient strength and ease of bending by carefully balancing dimensional relationships
3Area of stationary object
If the first substrate length proportion is optimized to minimize dead space, then the area utilization is improved, but the structural stability is worsened
Solution Approach 1:
The first substrate is divided into first and second sub-substrates with a specific length ratio (1:50 to 1:200). This segmentation minimizes dead space by optimizing the distribution of substrate material - the first sub-substrate provides necessary structural support while the second sub-substrate is minimized to accommodate only the bending area, thus maximizing area utilization while maintaining stability
Solution Approach 2:
The patent employs a composite structure combining the first substrate (hard material) with the second substrate (soft material). This composite approach allows the first substrate to be optimized for minimal dead space through precise dimensional control, while the second substrate provides flexibility and structural support, together maintaining overall structural stability
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 solution reduces or minimizes dead space, enabling easier bending and attachment of components, thus enhancing the aesthetic appeal and immersion of the display device while reducing the risk of damage during bending.
Implementation Method 1
removing a portion of the first mother substrate in a bending area by spraying an etchant onto a second surface of the first mother substrate that is opposite to the first surface
Implementation Method 2
irradiating a laser on the second surface along edges of the display cells
Data Source
AI summary
Provided are a display device and a method for manufacturing the display device. A display device includes a second substrate including a soft material, light-emitting elements above the second substrate, and a first substrate below the second substrate, including a hard material, and further including a second sub-substrate on one side of a bending area where the second substrate is bent, and a first sub-substrate on another side of the bending area, below the light-emitting elements, having a length that is about 50 times to about 200 times a length of the second sub-substrate, and including a first surface, a second surface opposite to the first surface, a first side surface between the first surface and the second surface, and adjacent to the bending area, and a first inclined surface between the first surface and the first side surface.