Flexible Display Layer Structure for Crack-Resistant Bending

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Solution Overview

Problem

Flexible display devices are prone to cracks in metal lines and substrates at bending areas, leading to defects and reduced reliability.

Innovation Solution

A display device design with a substrate, a display element layer sealed by an encapsulation layer, a polarizing layer, and protection layers with varying thicknesses and spacing, including a support layer to prevent cracking during bending.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the display device is made flexible to enable folding and bending, then adaptability and versatility are improved, but cracks are frequently generated in metal lines and substrates at bending areas, reducing reliability

Engineering Contradiction:

ImproveflexibilityVSAvoidcrack resistance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies flexible thin film structures throughout the display device, including the substrate, encapsulation layer, protection layers, and polarizing layer. These thin film structures enable the device to be folded and bent while maintaining integrity, directly addressing the flexibility requirement while preventing cracks through the inherent flexibility of thin film materials

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the physical parameters of the protective layers by controlling their thicknesses. The first protection layer has a first thickness and the second protection layer has a second thickness different from the first, optimizing the mechanical properties for flexibility and crack resistance. This parameter optimization allows the device to withstand bending stresses without cracking

Inventive Principle:

Principle #35Parameter changes

2Reliability

If protection layers are added to prevent cracks, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvecrack resistanceVSAvoidstructure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protection layers serve multiple functions simultaneously: they protect the display element layer from mechanical damage, provide structural support during bending, and contribute to the overall flexibility of the device. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity while maintaining improved reliability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250372005A1Display device and method of manufacturing the same

Publication Date: 2025.12.04 SAMSUNG DISPLAY CO LTD

AI summary

A display device according to an embodiment of the present disclosure may include a substrate, a display element layer on the substrate, an encapsulation layer on the display element layer to seal the display element layer, a polarizing layer on the encapsulation layer, a first protection layer on the substrate and spaced apart from the polarizing layer, and a second protection layer on the substrate and covering a portion of the first protection layer, wherein the first protection layer has a thickness that is greater than a thickness of the second protection layer.