Flexible Display Curvature Reduction via Segmented Support Layers
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Solution Overview
Problem
Flexible display devices with expandable capabilities face limitations due to visually recognizable curvature when folded, affecting surface quality and user experience.
Innovation Solution
A display device design featuring a display panel with distinct regions supported by different layers and resin portions, where the first resin portion fills the gap between the cover layer and the first support layer, providing a uniform and flat surface, and additional resin portions and support bars enhance surface quality by minimizing curvature visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a flexible display device uses a single support layer below the display panel, then the structure is simple, but the curvature is visually recognized and surface quality deteriorates
Solution Approach 1:
The support structure is divided into multiple distinct layers: a first support layer directly below the display panel, a second support layer below the first support layer, and a third support layer below the second support layer. Each layer has different thickness and material properties, creating a graduated support system that prevents curvature while maintaining structural integrity.
Solution Approach 2:
Different regions of the support structure have different properties. The first support layer has greater thickness than the second support layer, which has greater thickness than the third support layer. This graduated thickness distribution provides localized support where needed most (near the display panel) while reducing support further away, eliminating curvature without excessive complexity.
2Length of stationary object
If the cover layer and first support layer are close together, then the device thickness is reduced, but the curvature becomes more pronounced and visible
Solution Approach 1:
The support structure is segmented into multiple layers with the first support layer positioned closer to the display panel and the second and third support layers positioned progressively further away. This segmentation allows the first support layer to provide immediate curvature correction while the thicker second and third layers provide gradual support, preventing the curvature issue that would occur with a single close layer.
Solution Approach 2:
The first support layer has greater thickness than the second support layer, which has greater thickness than the third support layer. This local variation in thickness provides enhanced support near the display panel where curvature is most problematic, while maintaining overall device thickness efficiency through reduced thickness in lower layers.
3Manufacturing precision
If multiple support layers with different thicknesses are used, then surface quality is improved, but the device complexity increases
Solution Approach 1:
The patent implements a graduated thickness distribution where the first support layer is thickest, the second support layer is intermediate, and the third support layer is thinnest. This local quality variation provides optimal curvature correction with minimal material usage, achieving high surface quality without proportionally increasing overall device complexity.
Solution Approach 2:
The support function is segmented across three layers with progressively different thicknesses and material compositions. This segmentation distributes the complexity across multiple simple, functionally-distinct layers rather than requiring one complex layer, making the overall structure more manageable and manufacturable.
4Ease of manufacture
If the first resin portion has uniform thickness, then the manufacturing process is simplified, but the curvature correction may be insufficient in certain regions
Solution Approach 1:
The resin support is segmented into multiple portions: a first resin portion between the cover layer and first support layer, a second resin portion between the first and second support layers, and a third resin portion between the second and third support layers. This segmentation allows each resin portion to be optimized for its specific location, with the first resin portion providing uniform thickness for ease of manufacture while lower resin portions can vary in thickness for enhanced curvature correction.
Data Source
AI summary
A display device includes a display panel including a first region and a second region arranged along a first direction, a cover layer below a rear surface of the display panel, and overlapping the first region, a first support layer below the rear surface of the display panel, overlapping the second region, and spaced apart from the cover layer along the first direction, a second support layer below the cover layer, overlapping the first region, and defining openings, and a first resin portion in a space between the cover layer and the first support layer.