Foldable Display With Flexible Substrate And Rigid Panels

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Solution Overview

Problem

Existing foldable displays face challenges such as sensitivity to moisture and oxygen for OLED panels, high costs for microLED and miniLED displays, and difficulties in making LCD panels flexible, leading to increased costs and complexity in encapsulation and manufacturing.

Innovation Solution

The use of flexible connectors, such as wavy connectors, between display panels and components, along with microLED or miniLED panels that can bend more than 180 degrees, and the integration of rigid and flexible panels to create an indistinguishable seam, reducing the need for additional encapsulation layers and lowering costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If OLED displays are used for foldable displays, then viewing experience is improved, but sensitivity to moisture and oxygen increases requiring additional protection

Engineering Contradiction:

Improveviewing experienceVSAvoidsensitivity to moisture and oxygen

Core Design Contradiction:

Illumination intensityVSObject-affected harmful factors

Solution Approach 1:

The patent uses flexible encapsulation layers comprising multiple thin film layers (including inorganic barrier layers and organic buffer layers) that conform to the flexible display panel. These thin film encapsulation layers provide moisture and oxygen protection while maintaining flexibility, allowing the display to be folded without compromising the OLED's sensitivity to environmental factors.

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If LCD panels are made foldable, then versatility is improved, but manufacturing difficulty and cost increase

Engineering Contradiction:

ImproveversatilityVSAvoidmanufacturing difficulty and cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent segments the display into different functional layers, with the liquid crystal layer and backlight assembly being the key components that enable folding capability. By separating the display into modular components (substrate, OLED/microLED layer, liquid crystal layer, backlight, encapsulation), the design achieves versatility while simplifying manufacturing compared to traditional rigid LCDs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the physical parameters of the display components to enable folding, specifically using flexible substrates and adjusting the thickness and material properties of encapsulation layers. This allows LCD panels to achieve foldability with reduced manufacturing complexity compared to conventional approaches.

Inventive Principle:

Principle #35Parameter changes

3Use of energy by moving object

If microLED and miniLED displays are used, then energy efficiency and stability are improved, but cost increases

Engineering Contradiction:

Improveenergy efficiencyVSAvoidcost

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent applies microLED or miniLED technology selectively in specific regions or portions of the flexible display rather than throughout the entire display area. This local application allows the system to achieve energy efficiency and stability benefits where needed while controlling overall manufacturing costs by combining microLED/miniLED sections with other display technologies in different regions.

Inventive Principle:

Principle #3Local quality

4Volume of moving object

If foldable displays are designed with bending capability, then space savings and protection are improved, but additional encapsulation layers are required

Engineering Contradiction:

Improvespace savingsVSAvoidadditional encapsulation layers

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

The patent employs flexible encapsulation layers made of thin film structures that provide the necessary protection against moisture and oxygen while accommodating the bending motion. These flexible encapsulation layers are designed with appropriate thickness and material composition to protect the display during folding without adding excessive complexity or volume.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent designs the encapsulation structure to follow curved geometries that match the folding pattern of the display. By shaping the encapsulation layers to conform to the curved bending path, the design provides effective protection while minimizing the number of layers needed and reducing overall structural complexity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS11606867B2Foldable displays and methods

Publication Date: 2023.03.14 THE HONG KONG UNIV OF SCI & TECH

AI summary

Various foldable, or flexible, displays and associated methods are enabled. For instance, a screen comprises a first rigid display at a first end of a surface of a flexible substrate. A second rigid display is at a second end of the surface of the flexible substrate. A flexible display is on the surface of the flexible substrate, between the first rigid display and the second rigid display, wherein a first section of the flexible substrate underneath the flexible display is thicker than a second section of the flexible substrate underneath the first rigid display or the second rigid display, and the first rigid display and second rigid display, and flexible display are covered with a protective foldable layer.