Flexible Display Folding-Area Filling Layer for Impact Resistance

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Solution Overview

Problem

Flexible display devices face durability issues when repeatedly bent or folded due to decreased durability in the bending or folding areas.

Innovation Solution

A display device with a base member featuring concave portions filled with a filling layer, composed of materials like acrylate, urethane acrylate, or silicone resin, is manufactured by applying a filling material using a slot die and curing it to form a filling layer that overlaps the folding area, ensuring no voids are present.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the flexible display device is repeatedly bent or folded, then portability and user convenience are improved, but the durability of the bending or folding area decreases

Engineering Contradiction:

Improveportability and user convenienceVSAvoiddurability of bending or folding area

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The base member is designed with a specific structure in the bending area, featuring a curved surface with a predetermined radius of curvature that matches the folding radius. This localized structural adaptation allows the display device to be folded without compromising overall durability, as the bending stress is distributed across the curved surface rather than concentrated at sharp edges.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

A filling layer is formed in advance within concave portions of the base member before the device is put into service. This filling layer acts as a cushioning element that absorbs and distributes stress during repeated folding operations, preventing durability degradation in the bending area while maintaining the flexibility needed for portability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If a filling layer is formed to improve impact resistance and folding characteristics, then durability is improved, but the manufacturing process complexity increases

Engineering Contradiction:

Improveimpact resistance and folding characteristicsVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The base member is designed with concave portions that are subsequently filled with a filling layer. This approach creates a structured, porous-like configuration that improves impact resistance and folding characteristics. The concave portions are formed through standard manufacturing processes, and the filling layer is applied using conventional coating or injection methods, thereby improving durability without significantly increasing manufacturing complexity.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The display device combines the base member material with a filling layer material to create a composite structure. This composite design enhances impact resistance and folding characteristics by leveraging the complementary properties of the two materials. The filling layer provides cushioning and stress distribution, while the base member provides structural support, achieving improved reliability through a relatively simple composite construction.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If the base member has a curved surface with predetermined radius of curvature, then folding characteristics are improved, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvefolding characteristicsVSAvoidcurved surface radius of curvature

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The base member is designed with a curved surface having a specific radius of curvature parameter that corresponds to the intended folding radius. By optimizing this geometric parameter during the design stage, the device achieves good folding characteristics. The curved surface can be formed using standard manufacturing techniques such as molding or bending processes, controlling the radius of curvature within acceptable tolerances without requiring extremely high manufacturing precision.

Inventive Principle:

Principle #35Parameter changes

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 enhances the impact resistance and folding characteristics of the display device, maintaining durability and preventing refractive index differences that could affect light emission.

Implementation Method 1

applying a filling material onto the base member using a slot die and attaching the base member on a display panel... curing it to form a filling layer

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Implementation Method 2

removing a gas remaining on a base member through a first suction member

Methodology Applied

Scientific EffectSuction: Suction

Implementation Method 3

increasing a surface energy of the base member by performing a plasma treatment on the base member by a plasma generating device

Methodology Applied

Scientific EffectPlasma treatment: Plasma

Data Source

PatentUS20250326208A1Display device and method of manufacturing the same

Publication Date: 2025.10.23 SAMSUNG DISPLAY CO LTD

AI summary

A display device includes a display panel having a first non-folding area, a folding area connected to the first non-folding area, and a second non-folding area spaced apart from the first non-folding area by the folding area. A base member is disposed on the display panel. The base member includes a pattern area including a plurality of concave portions overlapping the folding area. The plurality of concave portions is spaced apart from each other in a first direction and has a depth in a second direction perpendicular to the first direction. A first filling layer fills the plurality of concave portions. The first filling layer includes at least one material selected from an acrylate, a urethane acrylate, and a silicone resin.