Dummy Window for Uniform Protective Layer Thickness
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Solution Overview
Problem
Existing display devices face challenges in achieving uniform thickness and enhanced impact resistance for their window protective layers, which affects the reliability and durability of the devices.
Innovation Solution
A method of manufacturing a display device involves forming a preliminary protective layer on a window member with a dummy window, pre-curing it, and then separating the dummy window to ensure uniform thickness and improved impact resistance, using materials like polyimide, polycarbonate, or polyethylene terephthalate, and subsequent polishing to maintain surface hardness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a protective layer is formed directly on the window without using a dummy window, then the manufacturing process is simpler, but the thickness of the protective layer becomes non-uniform at the edges
Solution Approach 1:
A dummy window is formed on the carrier film before the actual window, and a protective layer is formed over both. The dummy window serves as a preliminary structure that guides the protective layer formation process, ensuring uniform thickness distribution. After the protective layer is formed and cured, the dummy window is removed, leaving a uniformly thick protective layer on the actual window.
Solution Approach 2:
The dummy window creates a template or copy of the desired protective layer configuration. By forming the protective layer over the dummy window structure, the process ensures that the protective layer thickness is uniform across the entire window surface, including edges, before the dummy window is removed.
2Strength
If the window protective layer is made thicker to improve impact resistance, then durability improves, but the overall device thickness increases
Solution Approach 1:
The protective layer is formed using composite material structures, combining multiple layers with different properties. This allows achieving high impact resistance and durability while maintaining controlled thickness. The use of dummy window during formation enables optimization of material distribution to maximize strength without excessive thickness.
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 approach enhances the reliability and durability of display devices by ensuring uniform thickness and improved impact resistance of the window protective layer, reducing the likelihood of damage from external impacts and maintaining camera resolution.
Implementation Method 1
The pre-curing of the preliminary protective layer may include light-curing the preliminary protective layer by a first light
Data Source
AI summary
A method of manufacturing a display device includes preparing a window member including a first window including a display area, and a second window adjacent to a first side surface of the first window, forming a protective member on an upper surface of the window member by forming a preliminary protective layer on a first upper surface of the first window and on a second upper surface of the second window, and pre-curing the preliminary protective layer, and separating the second window from the first side surface.