Flexible Substrate Spacer Alignment for Display Bending
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Solution Overview
Problem
The challenge in manufacturing display devices with flexible substrates is preventing the reinforcing film from interfering with spacers during bending, which can lead to wiring disconnection or damage due to bending stress.
Innovation Solution
A method involving a flexible substrate with a display area, frame area, and terminal area, where a spacer with a recessed first bottom surface and alignment marks is used, and a reinforcing film is cut to match the spacer's dimensions, allowing the spacer to guide the bend without interference from the reinforcing film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcing film is disposed inside the bend of a flexible substrate, then the flexibility and strength of the substrate are improved, but the reinforcing film may interfere with spacers and cause wiring disconnection or damage
Solution Approach 1:
The flexible substrate is divided into distinct functional areas: a display area, a frame area, a bent area, and a terminal area. The reinforcing film is selectively disposed only in the bent area rather than covering the entire substrate, segmenting the reinforcement function to where it is most needed while avoiding interference with spacers in other areas.
Solution Approach 2:
The reinforcing film is applied locally to the bent area where additional strength and flexibility are required, rather than uniformly across the entire substrate. This localized reinforcement provides the necessary mechanical properties where bending occurs while leaving other areas free for spacer placement and wiring without interference.
2Area of stationary object
If the frame area is narrowed to downsize the display device, then the display area can be expanded, but the bending stress on the bent part increases causing wiring disconnection
Solution Approach 1:
The reinforcing film is disposed in the bent area in advance, before the bending operation is performed. This preliminary reinforcement prepares the bent area to withstand the increased bending stress that will occur when the frame is narrowed and the bending radius is reduced, preventing wiring disconnection.
Solution Approach 2:
The reinforcing film acts as a cushioning element that absorbs and distributes the bending stress in the bent area before the stress can cause damage to the wirings. This beforehand cushioning protects the wiring connections from the increased mechanical stress resulting from the narrowed frame design.
Data Source
AI summary
A method for manufacturing a display device includes the steps of preparing a spacer that includes a first alignment mark, forming a notch on a back reinforcing film and cutting the back reinforcing film in a size corresponding to a size of a first bottom surface, disposing the back reinforcing film on a back surface side of a display area, disposing the spacer on a back surface side of a flexible substrate, and bending a bent area so as to conform to a shape of the spacer and disposing a terminal area on a back surface side of the spacer. In the step of disposing the spacer, viewed from the back surface side of the flexible substrate, the spacer is positioned on the back reinforcing film based on a position of the notch and a position of the first alignment mark.