Foldable Display Plate Openings for Impact and Wrinkle Control

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Solution Overview

Problem

Flexible display devices face challenges with impact resistance and folding reliability due to the use of thin polymer substrates, which are prone to damage and wrinkles during folding.

Innovation Solution

The display device incorporates a plate below the display panel with openings defined in the folding area, where the openings are continuously extended and have specific width and separation distance ratios to enhance impact resistance and folding reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a thin polymer substrate is used to enable folding, then flexibility and foldability are improved, but impact resistance and structural strength deteriorate

Engineering Contradiction:

ImprovefoldabilityVSAvoidimpact resistance

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent combines a thin polymer substrate with a plate structure to create a composite construction. The plate serves as a reinforcement layer that provides impact resistance while the polymer substrate maintains flexibility and foldability. This composite approach allows the display device to benefit from both the flexibility of the polymer and the strength of the plate without compromising either property.

Inventive Principle:

Principle #40Composite materials

2Strength

If a solid plate is used to improve impact resistance, then strength is improved, but folding reliability deteriorates due to wrinkles and stress concentration

Engineering Contradiction:

Improveimpact resistanceVSAvoidfolding reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The plate is divided into multiple segments by forming openings that extend in the first direction. These openings segment the plate structure, allowing it to flex and fold more reliably by distributing stress across multiple smaller sections rather than concentrating it in a single solid structure. This segmentation reduces wrinkle formation while maintaining overall impact resistance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The plate incorporates openings that create a porous or perforated structure. This porous design allows the plate to maintain its strength and impact resistance while improving folding reliability by reducing stress concentration and allowing controlled flexing. The openings enable the plate to adapt to folding movements without compromising structural integrity.

Inventive Principle:

Principle #31Porous materials

3Reliability

If openings are added to the plate to improve folding reliability, then folding reliability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvefolding reliabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent uses laser processing to create the openings in the plate, replacing traditional mechanical cutting or drilling methods. This substitution simplifies manufacturing by enabling precise, complex opening patterns to be created efficiently through laser ablation, reducing the overall manufacturing complexity despite the added feature of openings in the plate structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If the width and separation distance of openings are optimized to improve impact resistance, then impact resistance is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveimpact resistanceVSAvoidopening dimension precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

Laser processing is used to create the openings with precise control over width and separation distance. The laser method enables accurate reproduction of the designed opening dimensions without requiring complex mechanical tooling or multiple processing steps, thereby achieving the required manufacturing precision while maintaining relatively simple manufacturing processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 improves the impact resistance and folding reliability of the display device, prevents wrinkles, and enhances product productivity while maintaining a visually seamless appearance.

Implementation Method 1

forming a plurality of openings in a preliminary plate using a laser

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS20250291391A1Display device, method of manufacturing the display device, and electronic device including the display device

Publication Date: 2025.09.18 SAMSUNG DISPLAY CO LTD

AI summary

A display device and a method of manufacturing a display device are disclosed. A display device includes a display panel including a folding area and a plate located below the display panel, and defining a plurality of openings extending continuously in a first direction and spaced apart from each other in a second direction intersecting the first direction, and a value obtained by dividing a width of each of the openings in the second direction by a separation distance of adjacent openings among the openings in the second direction is 0.05 to 0.5.