Foldable Display Outer Structure With Dual-Modulus Layers
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Solution Overview
Problem
The increasing complexity and cost of fabricating display devices, particularly in bendable and foldable designs, are exacerbated by the need to assemble various parts as modules, leading to significant dead space and reduced durability.
Innovation Solution
A display device design featuring a display module surrounded by an outer structure with differing Young's moduli layers, where the first outer layer has a lower modulus than the second, and a method of fabrication involving molds and pastes to minimize dead space and enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If display devices are fabricated as modular components and assembled together, then manufacturing complexity and cost increase, but device assembly flexibility and repairability improve
Solution Approach 1:
The display device is divided into multiple modules (first display module, second display module, etc.) that can be independently fabricated and then assembled together. Each module contains complete functional elements including display panels, outer structures, and bonding layers, enabling modular manufacturing and assembly while maintaining overall device functionality
Solution Approach 2:
Multiple display modules are arranged in an overlapping configuration where portions of adjacent modules extend beyond each other's boundaries. The outer structures of neighboring modules overlap and bond together, creating a nested arrangement that eliminates dead spaces while maintaining modular construction benefits
2Ease of manufacture
If modular display devices are assembled with gaps between modules, then manufacturing and assembly become simpler, but dead space increases and structural integrity deteriorates
Solution Approach 1:
The solution transitions from a one-dimensional linear arrangement of modules to a two-dimensional overlapping configuration. Modules are positioned such that their outer structures extend beyond module boundaries in the lateral dimension, creating overlapping regions that eliminate dead spaces while maintaining manufacturing simplicity
Solution Approach 2:
Adjacent display modules are merged through overlapping outer structures that bond together. The outer structure of one module overlaps with the outer structure of the neighboring module, creating a continuous bonded interface that eliminates gaps and dead spaces while preserving modular construction advantages
3Ease of manufacture
If uniform outer structure layers are used across all modules, then manufacturing process becomes simpler, but durability and impact resistance are reduced
Solution Approach 1:
The outer structure of each module is divided into multiple layers with different Young's moduli. The first outer layer has a lower Young's modulus for flexibility, while the second outer layer has a higher Young's modulus for durability. This layered configuration with spatially varying mechanical properties enhances impact resistance and overall device reliability while maintaining manufacturing feasibility
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 solution effectively reduces dead space between modules and enhances the durability of the display device, improving its structural integrity and ease of folding.
Implementation Method 1
A Young's modulus of the first outer layer is different than a Young's modulus of the second outer layer. In an embodiment, in the Young's modulus of the first outer layer is smaller than the Young's modulus of the second outer layer.
Data Source
AI summary
A display device include a display module and an outer structure surrounding the display module. The display module includes: a display panel having a folding area and a non-folding area at a side of the folding area; an upper module on an upper side of the display panel; and a lower module on a lower side of the display panel. The outer structure includes: a first outer layer adjacent to the display module; and a second outer layer on an outer side of the first outer layer. A Young's modulus of the first outer layer is different than a Young's modulus of the second outer layer.