Hierarchical Flexible Display Modules for Large Rollable Screens
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Solution Overview
Problem
Large display devices face challenges with weight and cost due to their size, as they become unwieldy and expensive to produce, especially when using glass substrates, which are difficult to bend and transport.
Innovation Solution
A rollable display device is designed with a transparent flexible cover and multiple flexible display modules arranged at specific intervals, using a hierarchical structure of flexible films and display chips, allowing for easy assembly and rolling, and utilizing roll-to-roll processing to maintain flexibility and reduce material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a glass substrate is used for large display devices, then the display device can achieve large size, but the weight increases to at least 100 kg and the device cannot be bent
Solution Approach 1:
The display device is divided into multiple flexible display modules (primary and secondary sub-modules) that can be independently manufactured and assembled. This segmentation allows each module to be lightweight and flexible, while collectively forming a large-sized display when assembled together on the transparent cover.
Solution Approach 2:
The patent replaces traditional rigid glass substrates with flexible transparent films (including the transparent cover and multiple flexible films in each display module). This substitution enables the display to be bent, rolled, and easily transported while maintaining large display area, directly resolving the weight and flexibility issues.
2Area of stationary object
If a glass substrate is used for large display devices, then the display device can achieve large size, but the device cannot be bent and is difficult to transport
Solution Approach 1:
The entire display structure is constructed using flexible transparent films instead of rigid glass, enabling the large-sized display to be bent into rolls for easy transportation and storage, while maintaining the required display area when unrolled and assembled.
Solution Approach 2:
The display device transitions from a static rigid structure to a dynamic flexible structure that can change shape between flat assembled state (for use) and rolled state (for transport), enhancing ease of operation and transportability.
3Area of stationary object
If the display device is made into a single large panel, then the screen size increases, but the yield decreases and cost increases significantly
Solution Approach 1:
The large display is segmented into multiple smaller flexible display modules that can be manufactured separately with higher yield, then assembled into the final large-sized display. This approach avoids the low yield associated with manufacturing single large panels while achieving the desired screen size.
Solution Approach 2:
The patent transitions from manufacturing a single large 2D panel to assembling multiple smaller modules in a modular architecture, adding the dimension of modularity to the manufacturing process. This enables parallel production of multiple modules, improving overall productivity and yield.
4Ease of operation
If multiple flexible display modules are arranged with intervals, then the device becomes rollable and flexible, but the structure becomes more complex
Solution Approach 1:
The display modules are arranged in a nested hierarchical structure with primary flexible films containing secondary sub-modules, which themselves contain display chips. This nesting organizes the complexity systematically, making the modular structure manageable while enabling rollability through the intervals between nested elements.
Data Source
AI summary
A large rollable display device includes flexible display modules arranged spaced apart from each other at first intervals on a rear surface of a transparent cover. Each of the flexible display modules includes primary sub-flexible display modules arranged spaced apart from each other at second intervals on a rear surface of a primary flexible film, and each of the primary sub-flexible display modules includes secondary sub-flexible display modules that are arranged spaced apart from each other at third intervals on a rear surface of a secondary flexible film.