Multi-Layer Foam Cushion for Flexible Display Surface Quality
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Solution Overview
Problem
Flexible display devices face issues with irregularities and visibility in folding areas, as well as inadequate impact resistance due to their deformable nature.
Innovation Solution
A display device incorporating multiple foam layers with different densities and porosity structures, including a high-density third foam layer closest to the display panel, a low-density second foam layer with high porosity, and a first foam layer with intermediate density and porosity, to enhance surface quality and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flexible display device is made deformable into various shapes, then ease of operation and portability are improved, but surface quality deteriorates with irregularities in folding areas
Solution Approach 1:
The cushion layer is segmented into multiple foam layers (first, second, and third foam layers) with different densities. The first foam layer has a first density, the second foam layer has a second density less than the first density, and the third foam layer has a third density greater than the first density. This segmentation allows each layer to perform different functions in managing surface irregularities while maintaining flexibility.
Solution Approach 2:
Different regions of the cushion layer have different densities tailored to specific functions. The third foam layer with higher density is positioned closer to the display panel to provide local support and reduce surface irregularities, while the second foam layer with lower density provides overall cushioning. This local quality differentiation addresses surface quality issues without compromising flexibility.
2Ease of manufacture
If the display device structure is simplified, then ease of manufacture is improved, but impact resistance deteriorates
Solution Approach 1:
The cushion layer uses a composite structure of multiple foam layers with different densities. The first foam layer has a first density, the second foam layer has a second density less than the first density, and the third foam layer has a third density greater than the first density. This composite material approach enhances impact resistance through layered density variation while maintaining relative manufacturing simplicity.
Solution Approach 2:
The cushion layer is positioned beforehand below the display panel to provide preventive protection against impacts. The multi-layer foam structure is designed in advance to absorb and distribute impact forces, protecting the display panel from damage before impacts occur.
3Device complexity
If a single foam layer is used, then device complexity is reduced, but surface quality and impact resistance deteriorate
Solution Approach 1:
The cushion layer is divided into three distinct foam layers with different densities. The first foam layer has a first density, the second foam layer has a second density less than the first density, and the third foam layer has a third density greater than the first density. This segmentation enables each layer to contribute differently to surface smoothness and impact protection.
Solution Approach 2:
The density parameter is varied across different foam layers to optimize performance. The third foam layer has a higher density for localized support, the second foam layer has a lower density for overall cushioning, and the first foam layer has an intermediate density. This parameter variation improves surface quality and impact resistance without excessive complexity.
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
The multi-layer foam structure improves surface smoothness, reduces visibility of irregularities, and provides enhanced protection against external impacts while maintaining flexibility.
Implementation Method 1
a cushion layer disposed below the display panel. The cushion layer may include a first foam layer having first pores, a second foam layer disposed above the first foam layer and having second pores, and a third foam layer disposed above the second foam layer and having third pores
Implementation Method 2
A porosity of the first foam layer may be less than a porosity of the second foam layer and may be greater than a porosity of the third foam layer
Data Source
AI summary
A display device includes a display panel and a cushion layer disposed below the display panel. The cushion layer includes a first foam layer having a first density, a second foam layer disposed above the first foam layer and having a second density less than the first density, and a third foam layer disposed above the second foam layer and having a third density greater than the first density. The third form layer is disposed closer to the display panel than the first foam layer. The display device provides improved surface quality, impact resistance, and restoration properties.