Flexible Display Protection Member with Dual-Layer Resin Impact Resistance
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Solution Overview
Problem
Conventional display devices lack effective impact resistance, especially in flexible and foldable designs, which can lead to damage during handling and repeated folding/unfolding, and existing manufacturing methods are inefficient in producing devices with enhanced protection features.
Innovation Solution
A display device comprising a protection member with a first layer having a storage modulus of 0.005-0.2 MPa and a second layer with a Young's modulus of 1-8 GPa, both made from materials like epoxy-based, urethane-based, or silicon-based resins, and optionally including silsesquioxane or silica nano particles, applied directly to the display module without a glass substrate, enhancing impact resistance and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protection member is added to improve impact resistance, then the device complexity increases
Solution Approach 1:
The protection member is divided into two distinct layers: a first protection layer with low storage modulus (0.005-0.2 MPa) for shock absorption, and a second protection layer with high Young's modulus (1-8 GPa) for structural support. This segmentation allows each layer to perform its specific function optimally, resolving the contradiction between impact resistance and structural integrity.
Solution Approach 2:
The patent employs composite material structure where the first protection layer uses soft resin materials (epoxy-based, urethane-based, or acrylic resin) and the second protection layer uses rigid resin materials with the same base types. This composite approach combines the advantages of both soft and hard materials to achieve superior impact resistance while maintaining device functionality.
2Reliability
If the protection member includes glass substrate for durability, then the weight increases
Solution Approach 1:
The patent replaces traditional glass substrates with organic resin-based protection layers that can be applied as thin films. These resin layers provide sufficient protection without the weight penalty of glass, and can be reapplied if damaged, effectively treating the protection as a replaceable component rather than a permanent structural element.
Solution Approach 2:
The protection member is constructed using thin film resin layers instead of thick glass substrates. The first protection layer (10-500 μm) and second protection layer (50-1000 μm) provide durable protection while maintaining flexibility and minimizing weight, enabling the display device to be folded and bent without the rigidity constraints of glass.
3Productivity
If high temperature curing is used for forming protection layers, then the manufacturing efficiency improves, but the display module may be damaged
Solution Approach 1:
The patent modifies the curing parameters by using low-temperature curing conditions (room temperature to 80°C) instead of high-temperature processing. This parameter change allows the protection layers to be formed without damaging the display module, while still achieving complete curing of the resin compositions through extended curing time or catalytic agents.
Solution Approach 2:
The display module is prepared in advance with appropriate surface treatment and alignment before applying the protection layers. The resin compositions are pre-mixed with suitable catalysts and additives to enable low-temperature curing. This preliminary preparation ensures that the subsequent low-temperature curing process proceeds efficiently without compromising module integrity.
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 proposed solution significantly improves the impact resistance and folding reliability of flexible display devices while maintaining a desired thickness, and the method enhances manufacturing efficiency by applying the protection layers at room temperature to 80°C, ensuring high impact resistance and reliability.
Implementation Method 1
a first protection layer having a storage modulus in a range of about 0.005 megapascal (MPa) to about 0.2 MPa
Implementation Method 2
a second protection layer disposed on the first protection layer, having a first thickness in a range of about 300 micrometers (μm) to about 1 millimeter (mm), and having a Young's modulus in a range of about 1 gigapascal (GPa) to about 8 GPa
Implementation Method 3
forming a preliminary first protection layer by curing the first resin composition, providing a second resin composition on the preliminary first protection layer, and forming a first protection layer and a second protection layer of the protection member by curing the preliminary first protection layer and the second resin composition
Data Source
AI summary
A display device includes a display module and a protection member disposed on the display module. The protection member includes a first protection layer and a second protection layer disposed on the first protection layer. The first protection layer has a storage modulus in a range of about 0.005 MPa to about 0.2 MPa at a room temperature. The second protection layer has a first thickness in a range of about 300 μm to about 1 mm, and has a Young's modulus in a range of about 1 GPa to about 8 GPa at the room temperature.