Folded Substrate Structure with Filling Member for Flexible Displays

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Solution Overview

Problem

In flexible display devices, the folding of terminal regions along the edges of substrates can lead to gaps between the folded and rear surfaces, which may cause line breaks when pressure is applied, reducing the display area to frame area ratio and compromising the structural integrity.

Innovation Solution

A substrate structure where the terminal region is folded back to the rear surface with a filling member between the folded portion and the rear surface, and adhesive materials are used to create overlapping portions that prevent gaps from forming, ensuring the lines remain intact under pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of moving object

If the terminal region is folded back to the rear surface to decrease the frame area, then the display area to frame area ratio is improved, but gaps form between the folded region and rear surface causing line breaks

Engineering Contradiction:

Improvedisplay area to frame area ratioVSAvoidline integrity in folded region

Core Design Contradiction:

Area of moving objectVSReliability

Solution Approach 1:

A filling member is introduced as an intermediary element between the folded terminal region and the rear surface. This filling member prevents gap formation and potential line breaks while maintaining the compact folded structure, thus resolving the contradiction between maximizing display area ratio and ensuring line integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The filling member is positioned in advance in the potential gap region before any pressure or stress is applied. This beforehand cushioning prevents the formation of gaps that would otherwise lead to line breaks, ensuring the reliability of the folded structure while maintaining the improved display area ratio.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Strength

If adhesive material is used to bond the folded peripheral region to the counter region, then structural integrity is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvestructural integrity of folded regionVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The bonding structure is segmented into distinct functional zones: a first overlapping portion with adhesive material for strong bonding, a second overlapping portion without adhesive for flexibility, and a third overlapping portion with adhesive for additional bonding. This segmentation allows the structure to achieve high structural integrity while maintaining ease of manufacture through modular assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the folded structure are assigned different qualities: adhesive material is applied only where needed for structural support (first and third overlapping portions), while the second overlapping portion remains adhesive-free to maintain flexibility and simplify manufacturing. This local differentiation optimizes both strength and ease of manufacture.

Inventive Principle:

Principle #3Local quality

3Area of stationary object

If the end of the substrate is bent 180 degrees to locate terminals on the rear surface, then the frame area is decreased, but gaps and line breaks occur under pressure

Engineering Contradiction:

Improveframe area sizeVSAvoidresistance to pressure in folded region

Core Design Contradiction:

Area of stationary objectVSStrength

Solution Approach 1:

The filling member serves as a mediator that prevents direct contact between the folded terminal region and the rear surface, eliminating gaps that would cause line breaks under pressure. This intermediary structure maintains the compact 180-degree fold configuration while significantly improving pressure resistance.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The folded structure employs a composite construction combining the substrate material, adhesive material in specific regions, and filling member material. This composite approach creates a structure that maintains the space-saving 180-degree fold while resisting pressure and preventing line breaks through the combined properties of different materials.

Inventive Principle:

Principle #40Composite materials

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 configuration increases the display area to frame area ratio and prevents line breaks in the folded regions, enhancing the structural integrity and display performance of flexible display devices.

Implementation Method 1

a first overlapping portion where a part of the peripheral region is bonded with the counter region with an adhesive material being provided therebetween

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS10147903B2Display device with overlapping substrate

Publication Date: 2018.12.04 MAGNOLIA WHITE CORP

AI summary

A display device includes a substrate including a peripheral region folded back to face a rear surface of the substrate, and a counter region facing the peripheral region; and a filling member held between the peripheral region and the counter region. The substrate is folded such that the display device includes a first overlapping portion where a part of the peripheral region is bonded with the counter region with an adhesive material being provided therebetween; a second overlapping portion where a part of the peripheral region is in direct contact with the filling member; and a third overlapping portion where a part of the peripheral region is bonded with the filling member with an adhesive material being provided therebetween.