Flexible Display Support Sheet Bridge Structure for Low-Defect Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing display devices face challenges in manufacturing flexible display devices with high defect rates due to complex manufacturing processes and structural integrity issues.
Innovation Solution
A manufacturing method for a display device involving a support sheet with specific structural features, including openings, branch parts, and dummy parts, which are easily manufactured by etching and separation techniques to reduce defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a support sheet is used between the display module and support part, then the structural integrity is improved, but the manufacturing complexity increases
Solution Approach 1:
The support sheet is segmented into multiple functional regions including a pattern part with openings matching the display module pattern, a peripheral part for support, and bridge parts connecting them. This segmentation allows each region to be optimized for its specific function while simplifying the overall manufacturing process through standardized etching patterns.
Solution Approach 2:
The support sheet is manufactured in advance as a separate component with pre-formed openings and bridge structures through etching. This preliminary fabrication allows the support sheet to be ready for assembly, reducing on-site manufacturing complexity and enabling modular assembly of the display device.
2Productivity
If the manufacturing process is simplified, then the productivity is improved, but the manufacturing precision may deteriorate
Solution Approach 1:
The bridge parts are designed with self-aligning features that automatically position the pattern part relative to the peripheral part during assembly. The geometric constraints of the bridge structures ensure precise alignment without requiring complex external positioning systems, maintaining manufacturing precision while simplifying the assembly process.
Solution Approach 2:
The thickness of the bridge parts is controlled within a specific range (50-200 micrometers) to optimize both manufacturability and functional performance. This parameter optimization allows the bridges to be thin enough for easy fabrication and assembly while maintaining sufficient strength to support the display module, thereby improving productivity without compromising precision.
3Adaptability or versatility
If the support sheet structure is optimized for flexibility, then the adaptability is improved, but the strength may worsen
Solution Approach 1:
The pattern part of the support sheet contains multiple openings that create a porous structure. This porosity reduces the overall stiffness of the support sheet, enabling it to flex and adapt to curved or flexible display modules while maintaining sufficient local strength at the bridge connections to provide structural support where needed.
Solution Approach 2:
The support sheet is divided into rigid peripheral parts for structural support and more flexible pattern parts with openings for adaptability. The bridge parts serve as transition zones with intermediate flexibility. This segmentation allows different regions to have optimized mechanical properties for their specific functions, achieving both flexibility and strength.
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 method enhances the manufacturing efficiency and reduces defect rates in flexible display devices by simplifying the production process and ensuring the support sheet does not damage the display module.
Implementation Method 1
forming an opening by etching the pattern part, forming a bridge by etching the peripheral part
Data Source
AI summary
A manufacturing method of a display device includes preparing a mother substrate including a pattern part and a peripheral part disposed on an outside of the pattern part, forming an opening by etching the pattern part, forming a bridge by etching the peripheral part to be located adjacent to a border between the pattern part and the peripheral part, separating the pattern part and the peripheral part from each other by cutting the bridge, and coupling the pattern part on one surface of a display module, wherein a thickness of the bridge is smaller than a thickness of the pattern part.