Flexible Display Panel Pre-bending with Contractive Film

Solution Overview

Problem

Existing manufacturing methods for flexible display devices face challenges in preventing bubble trapping when laminating a flat display panel onto a bent transparent window, which increases production time and costs due to the need for expensive vacuum equipment.

Innovation Solution

A method involving a contractive film, such as a polyolefin resin-based film, is applied to a flexible display panel, allowing it to be pre-bent and then attached to a transparent window using an optically clear adhesive, ensuring a smooth attachment process that avoids bubble formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a flat display panel is laminated onto a bent transparent window using conventional methods, then the display device can be manufactured, but bubble trapping occurs and expensive vacuum equipment is required

Engineering Contradiction:

Improvebubble-free attachmentVSAvoidvacuum equipment

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The display panel is pre-bent to match the curved shape of the transparent window before lamination. This preliminary deformation ensures that when the panel is attached to the bent window, the surfaces conform properly without trapping bubbles, eliminating the need for complex vacuum equipment.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The physical state of the display panel is changed from flat to bent/conformed to match the window's curvature. This parameter change in shape allows the panel to be attached smoothly to the bent transparent window without bubble formation, simplifying the manufacturing process.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If conventional lamination methods are used without pre-bending, then the manufacturing process is simple, but bubble trapping increases and production time increases

Engineering Contradiction:

Improveproduction timeVSAvoidbubble trapping

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The display panel is pre-bent to match the curved shape of the transparent window before lamination. This preliminary deformation ensures that when the panel is attached to the bent window, the surfaces conform properly without trapping bubbles, eliminating the need for complex vacuum equipment.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The physical state of the display panel is changed from flat to bent/conformed to match the window's curvature. This parameter change in shape allows the panel to be attached smoothly to the bent transparent window without bubble formation, simplifying the manufacturing process.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the display panel is pre-bent before attachment, then bubble trapping is prevented, but an additional contractive film and process step are required

Engineering Contradiction:

Improvebubble-free attachmentVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

A contractive film is introduced as an intermediary component that is attached to the display panel and then constricted to bend it into the desired curved shape. This intermediary tool enables the pre-bending process without requiring complex equipment or multi-step procedures, maintaining ease of manufacture while preventing bubble trapping.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 reduces the likelihood of bubble trapping and shortens the manufacturing process, making it more efficient and cost-effective by using a contractive film to pre-bend the display panel and attach it to a transparent window with an optically clear adhesive.

Implementation Method 1

Bending the flexible display panel may include ultraviolet (UV) light irradiation

Methodology Applied

Scientific EffectUV light irradiation: Photopolymerisation

Implementation Method 2

Bending the flexible display panel may include thermal energy application

Methodology Applied

Scientific EffectThermal energy application: Heating

Implementation Method 3

Bending the flexible display panel may include pressure energy application

Methodology Applied

Scientific EffectPressure energy application: Compression

Implementation Method 4

Attaching the contractive film to the flexible display panel may include attaching the contractive film to a bottom of the flexible display panel by using a pressure sensitive adhesive (PSA)

Methodology Applied

Scientific EffectPressure sensitive adhesive: Adhesive

Implementation Method 5

Attaching the flexible display panel to the transparent window may include attaching the flexible display panel and the transparent window to each other by an optically clear adhesive (OCA) film

Methodology Applied

Scientific EffectOptically clear adhesive: Adhesive

Data Source

PatentUS9718263B2Manufacturing method of flexible display device

Publication Date: 2017.08.01 SAMSUNG DISPLAY CO LTD

AI summary

Provided is a manufacturing method of a flexible display device, including locally deforming a transparent window; attaching a contractive film to a flexible display panel including a display area implementing an image; bending the flexible display panel by applying energy to the contractive film; and attaching the flexible display panel to the transparent window.