Segmented Display Support Layer for Lower Weight and Bend Strength
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Solution Overview
Problem
Bendable display modules, particularly those with OLED folding screens, face issues of high weight due to metal support layers and high processing costs for non-metallic materials, limiting cost-effective batch production.
Innovation Solution
A display module design using a combined support structure with different density materials, where a metal third support element in the bending region is integrated with non-metal first and second support elements in non-bending regions, featuring splicing seams filled with thermoplastic material and a planarization layer to reduce weight and processing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal plate is used as a support layer to improve support and flatness, then the structural strength is improved, but the overall weight of the display module increases
Solution Approach 1:
The support layer is divided into multiple segments with different material compositions. The first and second support layers use low-density non-metallic materials (carbon fiber or glass fiber), while the third support layer in the bending region uses a metal material. This segmentation allows each region to be optimized for its specific function while reducing overall weight.
Solution Approach 2:
Different regions of the support layer are assigned different material properties. Non-metallic materials are used in non-bending regions where high strength-to-weight ratio is needed, while metal material is used in the bending region where flexibility and structural integrity during bending are critical. This local differentiation resolves the contradiction between weight reduction and structural strength.
2Weight of moving object
If non-metallic materials such as carbon fiber and glass fiber are used for the support layer to reduce weight, then the weight is reduced, but the processing cost increases due to laser treatment requirements
Solution Approach 1:
The support layer is segmented into different material regions, with the third support layer in the bending region made of metal material that can be processed by chemical etching. This segmentation allows the use of cost-effective chemical etching for the critical bending region while maintaining weight reduction benefits in other regions.
Solution Approach 2:
The material parameter (density and processing characteristics) is changed based on the functional requirements of different regions. By using metal material for the third support layer, the processing method changes from laser treatment to chemical etching, significantly reducing processing costs while maintaining the weight reduction advantage of using non-metallic materials in other regions.
3Adaptability or versatility
If a hollowed-out structure is formed in the bending region to improve bending performance, then the bending flexibility is improved, but the structural strength may be compromised
Solution Approach 1:
The third support layer in the bending region uses metal material with appropriate mechanical properties to maintain structural strength while allowing the hollowed-out structure to provide bending flexibility. The metal material's inherent strength compensates for the reduced material volume, resolving the contradiction between flexibility and strength.
Solution Approach 2:
The support structure uses a composite of different materials (non-metallic materials in first and second support layers, metal material in third support layer) to achieve both weight reduction and maintained structural integrity. The combination of materials allows the hollowed-out structure to provide flexibility while the metal framework maintains strength.
Data Source
AI summary
The present disclosure provides a display module, including a first support element and a second support element respectively located in a first non-bending region and a second non-bending region of the display module, and a third support element located in a bending region of the display module. A density of the third support element is greater than that of the first support element and the second support element. The present disclosure integrates two materials with different densities. The first support element and the second support element are made of materials with lower densities, thereby reducing the weight of the display module.