Flexible Pad Geometry for Display Lamination Stress Relief
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Solution Overview
Problem
Conventional display device lamination processes often result in stress concentration and damage to display panels, particularly at physically weak areas like holes, due to uneven pressure distribution during the attachment of protective windows.
Innovation Solution
A flexible pad with a specifically designed geometry, including a generally straight area, a first inclined area, and a second inclined area with varying thicknesses and inclination angles, is used to distribute pressure evenly and reduce stress on the display panel, featuring a silicone resin composition to enhance flexibility and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional pressing member (silicon pad) is used for lamination, then conformal contact of the display panel and protective window is achieved, but stress concentration occurs at physically weak areas (holes) causing damage to the display panel
Solution Approach 1:
The pressing member incorporates an inclined area with a specific geometric configuration (first inclined area and second inclined area with different inclination angles) positioned to overlap the hole area. This creates localized structural differentiation where the inclined areas provide stress relief exactly where needed (at the hole location) while maintaining pressing function in other regions. The local geometric modification directly addresses the stress concentration problem at the physically weak hole area.
Solution Approach 2:
The pressing member features inclined areas with curved or angled surfaces instead of flat surfaces. The first inclined area has a first inclination angle and the second inclined area has a second inclination angle, creating a stepped curved profile. This curvature distributes the pressing force more evenly across the hole area, preventing stress concentration that would occur with a flat pressing surface.
2Productivity
If uniform pressure is applied during lamination, then efficient attachment is achieved, but gas bubbles become trapped between the display panel and protective window
Solution Approach 1:
The inclined areas are positioned to overlap the hole area before the lamination process begins. During pressing, the inclined geometry creates a progressive contact sequence where the display panel makes contact with the protective window in a controlled manner, allowing gas to escape from the hole area before full attachment occurs. This preliminary geometric arrangement prevents bubble trapping during the attachment process.
3Ease of manufacture
If a simple flat pressing member is used, then manufacturing is simple, but pressure distribution is uneven causing damage to weak areas
Solution Approach 1:
The pressing member is divided into distinct functional areas: a generally straight area, a first inclined area, and a second inclined area. Each segment serves a specific purpose in the pressure distribution pattern. The segmented structure allows for controlled pressure application where the inclined areas create gradual pressure transitions while the straight area provides stable pressing force, achieving uniform pressure distribution without excessive manufacturing complexity.
Data Source
AI summary
According to one aspect of the invention, a flexible pad for a display device lamination process includes: a generally straight area having an upper surface defining substantially the same height along a first direction and a generally convex shape along a second direction generally perpendicular to the first direction; a first inclined area having a first upper surface inclined along the first direction at a first inclination angle and being generally flat along the second direction; and a second inclined area disposed between the first inclined area and the generally straight area, wherein the second inclined area has a second upper surface inclined along the first direction at a second inclination angle smaller than the first inclination angle.