Flexible Display Panel Bending via Material Layer Segmentation
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Solution Overview
Problem
In flexible AMOLED display devices, the large total thickness of the support film and optical clear adhesive layer causes stress between the PI substrate and the support film, preventing complete bending and leading to cracked metal connection points when the display panel is bent towards the optical clear adhesive layer.
Innovation Solution
A method involving forming a material layer on a display panel, removing a portion of the material layer outside the effective display region, and bending the panel to create a U-shaped structure, where the second and third areas of the panel are on either side of the material layer, reducing stress and allowing complete bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the support film and optical clear adhesive layer are kept intact, then the structural integrity is maintained, but stress accumulates preventing complete bending and causing cracks
Solution Approach 1:
The support film is segmented into multiple regions: a first region where the optical clear adhesive layer is removed, allowing free bending; and second and third regions where the adhesive layer remains, maintaining structural integrity. This segmentation enables differential behavior across the support film, combining flexibility in the bending zone with strength in the structural zones.
Solution Approach 2:
Different regions of the support film are given different properties: the first region is made flexible and bendable by removing the adhesive layer, while the second and third regions maintain their original structural strength. This local differentiation allows the same component to simultaneously achieve bending capability and structural integrity in different locations.
2Ease of operation
If the material layer is removed from the first area, then bending stress is reduced enabling complete bending, but the structural support in that region is weakened
Solution Approach 1:
The support structure is divided into functional segments: the first area serves as a bending zone where material removal creates flexibility, while the second and third areas serve as structural zones that maintain support. This segmentation allows the system to achieve both bending capability and structural support through spatial differentiation.
3Shape
If the display panel is bent towards the optical clear adhesive layer, then the narrow border design is achieved, but the metal connection points crack due to stress
Solution Approach 1:
The optical clear adhesive layer is extracted (removed) from the first area where bending occurs, eliminating the source of stress that would otherwise cause metal connection points to crack. This selective removal allows the display panel to be bent into the desired narrow border configuration without compromising the reliability of the connection points.
Solution Approach 2:
The adhesive layer is removed in advance from the bending zone to prevent stress accumulation before bending occurs. This preliminary action eliminates the harmful stress that would otherwise develop during bending and cause cracking of the metal connection points, thereby protecting the structural integrity before the damaging event occurs.
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
Enables the display panel to be bent completely, achieving a narrow border design without cracking, by removing material from the first area to avoid stress between the PI substrate and the material layer.
Implementation Method 1
illuminating the first area from the first face of the display panel using a laser, such that the portion of the optical adhesive layer located in the first area is heated to be cracked and degraded
Implementation Method 2
illuminating the optical adhesive layer left on the display panel using an ultraviolet light to cure the optical adhesive layer left on the display panel
Data Source
AI summary
A display device and a method for manufacturing a display device are provided. The method includes: forming a material layer on a first face of a display panel; forming a touch panel and a polarizer sequentially on a second face of the display panel, the display panel having an end projecting beyond lateral faces of the touch panel and the polarizer; removing a portion of the material layer located in a first area on the display panel, the first area being located out of an effective display region of the display panel; and bending the first area of the display panel towards the first face such that a second area and a third area of the display panel are located on both sides of the material layer respectively, wherein the second area and the third area are connected to two ends of the first area respectively.