Flexible Substrate Folding with Magnetic Jig and Recessed Alignment
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Solution Overview
Problem
Existing flexible display devices face challenges in achieving accurate folding precision due to warping during manufacturing, which can lead to broken wires when folding at the wiring portion.
Innovation Solution
A method involving a substrate with a magnetic jig and plate system for securing and folding the flexible substrate, utilizing alignment markers and a spacer to maintain curvature and prevent wire breakage, ensuring precise folding and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the flexible substrate is folded at the wiring portion to reduce bezel size, then the display device achieves a narrower bezel and smaller overall size, but the substrate warping during manufacturing causes inaccurate folding precision and wire breakage
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses in the jig before substrate folding. These recesses are created in advance to match the expected substrate warp shape, allowing the substrate to be properly positioned and folded despite its warping. This preliminary preparation of the folding environment resolves the contradiction by accommodating substrate deformation while maintaining precise folding at the wiring portion.
Solution Approach 2:
The patent uses a specially designed jig as an intermediary between the substrate and the folding process. The jig includes recesses that mediate the interaction between the warped substrate and the folding operation, providing a controlled environment for accurate folding. This intermediary structure enables precise folding despite substrate warping, resolving the contradiction between bezel reduction and manufacturing precision.
2Productivity
If the substrate is folded without proper positioning, then the folding process is simpler and faster, but the alignment accuracy deteriorates leading to wire breakage
Solution Approach 1:
The patent applies self-service by designing the jig with recesses that automatically guide and position the substrate during folding. The recesses are shaped to accommodate the substrate's natural warp, allowing the substrate to self-align within the recess without requiring complex external positioning mechanisms. This maintains high productivity while ensuring accurate alignment and preventing wire breakage.
Solution Approach 2:
The patent changes the geometric parameters of the jig's recesses to match the substrate's warp characteristics. By adjusting the recess depth, width, and shape to correspond with the expected substrate deformation, the system achieves accurate alignment automatically. This parameter matching enables both efficient processing and high precision, resolving the contradiction between productivity and measurement precision.
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
This method enhances folding precision, preventing wire breakage and maintaining the structural integrity of the display device by correcting warp and ensuring accurate alignment during the folding process.
Implementation Method 1
locating a plate formed of a magnetic material on the substrate to secure the substrate by a magnetic force
Data Source
AI summary
A method for producing a display device includes locating a substrate, including a plurality of pixels, on a jig including a magnet; locating a plate formed of a magnetic material on the substrate to secure the substrate; and folding back an end portion of the substrate in a state where the substrate is held between the jig and the plate.