Flexible Multi-Layer Cover Lens Stack for Foldable Display Durability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flexible or foldable display devices face challenges with cover lenses that are brittle, leading to poor flexibility and susceptibility to scratches, requiring replacement and incurring high costs and time.
Innovation Solution
A flexible cover lens assembly comprising a glass layer, adhesion promotion layer, anti-reflectance layer, dry hardcoat layer with nano-indentation hardness between 1 GPa to 5 GPa, and anti-fingerprint coating layer, enhancing flexibility and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid display cover lens layer is used to prevent damage to underlying layers, then protection against scratches and damage is improved, but weight and size of the device increase
Solution Approach 1:
The patent applies a flexible polymer cover lens instead of a rigid glass cover lens. The flexible cover lens is formed from a polymer material that can be bent and folded, providing protection against scratches and damage while significantly reducing the weight and size of the device compared to traditional rigid cover lenses.
Solution Approach 2:
The patent uses a multi-layer composite structure consisting of a flexible polymer base layer with integrated functional layers including adhesion promotion layers, anti-reflectance layers, hardcoat layers, and anti-fingerprint coatings. This composite structure combines the flexibility of polymer with the protective and optical properties of various functional materials.
2Adaptability or versatility
If the thickness of glass is reduced to improve flexibility, then flexibility is improved, but strength and scratch resistance deteriorate
Solution Approach 1:
The patent employs a multi-layer composite structure where a flexible polymer base layer is combined with functional layers including adhesion promotion layers, anti-reflectance layers, hardcoat layers, and anti-fingerprint coatings. This composite approach provides both flexibility and scratch resistance by integrating materials with different properties.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the cover lens by using polymer materials with specific molecular weights, cross-linking densities, and compositional ratios. These parameter changes enable the material to achieve both flexibility and adequate strength without relying on thin glass.
3Adaptability or versatility
If chemical modification of glass is applied to increase critical strain, then flexibility is improved, but the entire cover must be replaced upon failure
Solution Approach 1:
The patent divides the cover lens into modular functional layers including a flexible polymer base layer, adhesion promotion layers, anti-reflectance layers, hardcoat layers, and anti-fingerprint coatings. This segmentation allows individual layers to be replaced or repaired independently, reducing the need to replace the entire cover upon failure.
Solution Approach 2:
The patent uses a flexible polymer material that can be easily replaced and is more cost-effective than glass. The polymer cover lens can be manufactured at lower cost and replaced more readily, reducing the economic and temporal impact of failures.
4Adaptability or versatility
If alternative materials are used to provide flexibility, then flexibility is improved, but abrasion and scratch resistance deteriorate
Solution Approach 1:
The patent uses a multi-layer composite structure combining a flexible polymer base layer with functional layers including adhesion promotion layers, anti-reflectance layers, hardcoat layers, and anti-fingerprint coatings. This composite structure provides both flexibility and abrasion resistance by integrating materials with complementary properties.
Solution Approach 2:
The patent applies different material properties to different layers of the cover lens structure. The base layer provides flexibility while subsequent functional layers provide localized protection against abrasion and scratches, with each layer optimized for its specific function.
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 provides improved flexibility and resistance to scratches, reducing the need for frequent replacements and maintaining optical performance.
Implementation Method 1
an adhesion promotion layer on the glass layer
Implementation Method 2
an anti-reflectance layer disposed on the adhesion promotion layer
Data Source
AI summary
Embodiments described and discussed herein generally relate to flexible or foldable display devices, and more specifically to flexible cover lens assemblies. In one or more embodiments, a flexible cover lens assembly contains a glass layer, an adhesion promotion layer on the glass layer, an anti-reflectance layer disposed on the adhesion promotion layer, a dry hardcoat layer having a nano-indentation hardness in a range from about 1 GPa to about 5 GPa and disposed on the anti-reflectance layer, and an anti-fingerprint coating layer disposed on the dry hardcoat layer.