Flexible Opaque-Region Structure to Prevent Thin-Film Cracking
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Solution Overview
Problem
Optical devices with flexible opaque-regions are prone to cracking or delamination when stretched, bent, or compressed, compromising their functionality and durability.
Innovation Solution
Incorporating a thin-film with multiple cavities and grooves in the opaque-region to enhance flexibility, allowing the region to bend or stretch without cracking or delamination, while maintaining high light-blocking capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the opaque-region is made as a solid thin-film to block light effectively, then light-blocking capability is improved, but flexibility and resistance to cracking are worsened
Solution Approach 1:
The opaque-region is designed with an array of cavities (through-holes) that penetrate the thin-film substrate. This porous structure allows the material to flex and stretch without cracking while the remaining material portions maintain light-blocking capability. The cavities create compliance in the otherwise opaque structure.
Solution Approach 2:
The opaque-region employs a composite structure combining the thin-film substrate material with the cavity pattern. This composite design integrates both light-blocking function (provided by the thin-film material) and flexibility (provided by the cavity pattern), resolving the contradiction between opacity and flexibility.
2Strength
If the thin-film is made continuous and solid to maintain structural integrity, then structural integrity is improved, but flexibility when bent or stretched is worsened
Solution Approach 1:
The thin-film substrate is segmented into multiple regions by creating an array of cavities. This segmentation divides the continuous film into discrete sections that can move independently, allowing the overall structure to flex and stretch while each segment maintains its structural integrity.
Solution Approach 2:
The引入 of cavities creates a porous structure that provides mechanical compliance. The porous architecture allows the thin-film to deform under stress without cracking, as the cavity walls can bend and the structure can accommodate strain through the porous network.
3Object-affected harmful factors
If the opaque-region is made thick to block all light, then light-blocking capability is improved, but flexibility and ease of stretching are worsened
Solution Approach 1:
The cavity structure effectively reduces the optical path length through the thin-film while maintaining light-blocking capability. The porous architecture allows light to be blocked by the remaining material portions without requiring the full thickness of a solid film, thereby preserving flexibility and stretchability.
Data Source
AI summary
Optical devices with different regions or pixels can form an image. An opaque-region 14 can be used to separate different pixels. Sometimes the optical device needs to be flexible, for elongation or stretching onto a curved surface. But, the opaque-region 14 can be damaged as it is stretched. A flexible optical device can include a modified opaque-region 14 for improved flexibility. The opaque-region 14 can include a thin-film 12 with multiple cavities 13, multiple zones 63, or both. Each zone 63 can have a shape optimized to both block incoming light and for flexibility. Each zone 63 can be encircled and separated from adjacent zones 63 by a groove 62. The cavities 13 and the separate zones 63 can allow the opaque-region 14 to bend or stretch without cracking or delamination of the thin-film 12.