Foldable Display Sealing Structure for Crack-Resistant Flexing

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Solution Overview

Problem

Foldable display devices are prone to defects such as cracks when folded due to stress concentration on the flexible substrate.

Innovation Solution

A display device with a flexible substrate featuring protruding portions having reverse-tapered surfaces and a recessed space filled with a self-repairing material in the sealing layer, which disperses stress and repairs defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a flexible substrate is folded to enable foldable display functionality, then the display device achieves portability and flexibility, but the members on the flexible substrate develop defects such as cracks

Engineering Contradiction:
ImproveflexibilityVSAvoiddefect resistance
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

A protruding portion is formed on the flexible substrate at the fold line position before folding occurs. This protruding portion creates a recessed space that acts as a cushioning structure, preventing direct contact and stress concentration between folded members. The recessed space is filled with sealing material to provide additional protection, thereby preventing cracks and defects before they can form during the folding operation.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The flexible substrate is segmented by forming a protruding portion that creates a recessed space at the fold line. This segmentation divides the continuous substrate into regions separated by the recessed space, allowing each region to move independently during folding without transmitting stress to adjacent members, thus preventing crack propagation.

Inventive Principle:
Principle #1Segmentation

2Adaptability or versatility

If the flexible substrate and members are made thinner to improve flexibility, then the display device becomes more portable and flexible, but the members become more susceptible to cracking and defects

Engineering Contradiction:
ImproveflexibilityVSAvoidcrack resistance
Core Design Contradiction:
Adaptability or versatilityVSStrength

Solution Approach 1:

The protruding portion creates a recessed space that serves as a cushioning structure, protecting thin members from stress concentration during folding. This cushioning effect compensates for the reduced inherent strength of thinner members, allowing them to flex without cracking.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The sealing material filling the recessed space forms a flexible protective layer that conforms to the thin members. This flexible sealing structure provides protection without adding significant thickness, maintaining the overall flexibility while enhancing crack resistance.

Inventive Principle:
Principle #30Flexible shells and thin films

3Reliability

If a protruding portion is formed on the flexible substrate to prevent defects, then the reliability is improved, but the device complexity increases

Engineering Contradiction:
Improvedefect resistanceVSAvoidsubstrate structure
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The protruding portion is formed by dividing the flexible substrate into regions separated by the protrusion. This segmentation can be achieved through standard fabrication processes like photolithography and etching, adding minimal complexity while effectively preventing defects at fold lines.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The protruding portion is localized only at critical fold line positions rather than throughout the entire substrate. This localized approach provides defect protection where needed most while maintaining the simplicity of the overall substrate structure in non-critical areas.

Inventive Principle:
Principle #3Local quality

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

Reduces the likelihood of cracks and enables self-repair of defects in the sealing layer, maintaining the display device's functionality.

Implementation Method 1

a sealing layer covering the side surface and an upper surface of the protruding portion, and a lower surface of the recessed space, the sealing layer containing a self-repairing material

Methodology Applied
Scientific EffectSelf-repairing material mechanism:

Data Source

PatentUS12635399B2Display device and method for producing display device
Publication Date: 2026.05.19 SHARP KK
  • US12635399B2 patent drawing
  • US12635399B2 patent drawing
  • US12635399B2 patent drawing

AI summary

A display device includes: a substrate that is flexible; a protruding portion having a side surface at least partially including a reverse-tapered surface on the substrate; and a sealing layer containing a self-repairing material. Furthermore, the display device includes a recessed space formed with the side surface of the protruding portion and a surface on which the protruding portion is formed. Moreover, the sealing layer convers: the side surface and an upper surface of the protruding portion; and a lower surface of the recessed space, and the recessed space has a side surface at least partially including the reverse-tapered surface.