Foldable Display Light Blocking Cushion Layer
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Solution Overview
Problem
In the manufacturing of display devices, the presence of impurities between the display panel and functional layers reduces display efficiency and manufacturing efficiency due to the use of adhesive layers.
Innovation Solution
A foldable display device design featuring a light blocking cushion layer directly contacting the base substrate and a metal layer directly contacting the cushion layer, both formed in situ without an adhesive layer, using materials like urethane acrylate, silicone, epoxy, and copper, with specific thicknesses and light absorption rates to enhance protection and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive layers are used to attach functional layers to the display panel, then the functional layers can be attached to the display panel, but impurities are inserted between the display panel and functional layers, reducing display efficiency and manufacturing efficiency
Solution Approach 1:
The patent removes the adhesive layer from the structure by having the light blocking cushion layer directly contact the base substrate and the metal layer directly contact the cushion layer. This extraction of the adhesive layer eliminates the source of impurities while maintaining the functional attachment between layers through direct contact and curing of the cushion layer material.
Solution Approach 2:
The patent combines the light blocking function and cushioning function into a single integrated layer (the light blocking cushion layer) that directly contacts both the base substrate and the metal layer. This merging eliminates the need for separate adhesive layers while achieving both protection and light blocking functions.
2Ease of manufacture
If adhesive layers are used to attach functional layers, then attachment is achieved, but manufacturing process efficiency is reduced due to impurity insertion
Solution Approach 1:
The adhesive layer is completely removed from the manufacturing process. The light blocking cushion layer serves as both the protective cushion and the bonding interface, directly contacting the base substrate and metal layer without requiring separate adhesive application steps, thereby improving manufacturing efficiency and precision.
3Reliability
If the light blocking cushion layer directly contacts the base substrate and metal layer, then impurity-related defects are eliminated, but the layer must perform both cushioning and light blocking functions simultaneously
Solution Approach 1:
The light blocking cushion layer integrates multiple functions: it provides mechanical cushioning/protection, blocks light (with light absorption rate of about 99.9% or more), and serves as the bonding interface between the base substrate and metal layer. This multi-functional integration eliminates the need for separate adhesive layers and reduces overall structure complexity.
Solution Approach 2:
The light blocking cushion layer material is designed to simultaneously provide cushioning properties, light blocking properties (through light blocking pigment), and adhesion properties, making it a universal layer that performs multiple critical functions in the display device structure.
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 design eliminates impurity-related defects, improving display efficiency and manufacturing process efficiency by directly forming the light blocking and metal layers on the display panel, ensuring high light absorption and shock protection without the need for adhesive layers.
Implementation Method 1
light absorption rate of the light blocking cushion layer may be about 99.9% or more
Implementation Method 2
curing the resin by applying heat of equal to or more than about 50 Celsius and equal to or more than about 80 Celsius
Implementation Method 3
curing the resin by irradiating the resin with ultraviolet (UV) light and then drying the resin naturally
Implementation Method 4
evaporating the solvent by applying heat of equal to or more than about 40 Celsius and equal to or less than about 80 Celsius to the ink
Implementation Method 5
sintering the metal particles by irradiating the ink with light
Data Source
AI summary
A display device includes a display panel including a base substrate and a plurality of pixels disposed on the base substrate, a light blocking cushion layer disposed under the display panel, wherein the light blocking cushion layer directly contacts the base substrate, and a metal layer disposed under the light blocking cushion layer, wherein the metal layer directly contacts the light blocking cushion layer.