Flexible Display Layer Bonded to 3D Faceplate
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Solution Overview
Problem
Current 3D display technologies face challenges in achieving high-quality optical coupling between layers, often resulting in visible defects like air bubbles, which compromise the user experience due to the limitations of flat, two-dimensional displays and rigid-to-rigid bonding processes.
Innovation Solution
A method involving a flexible display layer bonded to a 3D faceplate using an adhesive layer, employing lamination techniques like roller lamination to ensure air-free contact and prevent voids, allowing for higher quality optical properties and easier manufacturing by utilizing a flexible-to-rigid lamination approach.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid 3D faceplate is bonded to a rigid display layer, then structural stability is improved, but air bubbles and voids are trapped causing poor optical coupling
Solution Approach 1:
The patent applies a flexible display layer instead of a rigid display layer when bonding to the 3D faceplate. The flexibility of this thin film allows it to conform to the curved surface of the faceplate during lamination, enabling air bubbles and voids to escape rather than become trapped. This resolves the contradiction by maintaining structural stability through proper bonding while achieving high optical coupling quality without defects.
2Manufacturing precision
If a flexible display layer is used, then lamination quality and optical coupling are improved, but design flexibility is reduced
Solution Approach 1:
The patent segments the display system into two distinct components: a flexible display layer optimized for lamination quality and optical coupling, and a rigid 3D faceplate that provides the desired design flexibility and structural form. By separating these functions into different components, the system achieves both high manufacturing precision during assembly and design versatility in the final product configuration.
3Ease of manufacture
If traditional rigid-to-rigid bonding is used, then manufacturing simplicity is maintained, but visible defects and poor user experience result
Solution Approach 1:
The patent replaces the traditional rigid display layer with a flexible thin film that can be laminated to the 3D faceplate. This flexible film allows air to escape during the bonding process, eliminating visible defects like bubbles and voids. The lamination process remains relatively simple while achieving superior optical coupling quality and user experience without visible defects.
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 method enhances the manufacturing process by eliminating air bubbles and voids, resulting in improved optical coupling and user experience through the creation of high-quality, 3D displays that can be curved or folded, offering greater design flexibility and usability.
Implementation Method 1
an adhesive layer can be used
Implementation Method 2
employing lamination techniques like roller lamination to ensure air-free contact
Data Source
Figure 1~3
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AI summary
Examples relate to a method (10) for forming a 3D display stack (20). The method (10) comprises providing (11) a flexible display layer (21), providing (12) at least one 3D faceplate (22), and attaching (13) the flexible display layer (21) to the at least one 3D faceplate (22). The method makes use of a rigid-to-flexible bonding or lamination technique which is less challenging for the elimination of trapped air between layers of the formed display stack which is beneficial for high quality displays.