Multilayer Glass Composite Display Cover for Weight Reduction
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Solution Overview
Problem
Current display covers in portable information handling systems face challenges in reducing weight without compromising structural rigidity, especially with the integration of user interface elements that can lead to stress concentrations and early failure such as cracks or fractures.
Innovation Solution
A multilayer composite display cover is manufactured by alternating layers of ultra-thin glass sheets and polymer coatings, with a ceramic coating applied to enhance hardness, using materials like ionic exchange-strengthened glass and polymers such as polyurethane, and vapor depositing crystalline ceramics like sapphire or zirconia for added strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the thickness of a display cover made of glass is reduced to decrease weight, then weight is reduced, but structural rigidity deteriorates
Solution Approach 1:
The patent applies composite materials by combining ultra-thin glass sheets with polymer coatings and ceramic coatings to create a multilayer composite display cover. This composite structure allows the use of thinner glass layers (reducing weight) while maintaining overall structural rigidity through the combined properties of multiple materials working together.
Solution Approach 2:
The display cover is segmented into multiple thin layers (ultra-thin glass sheets, polymer coatings, ceramic coatings) rather than using a single thick glass layer. This segmentation allows each layer to be optimized for specific functions while collectively providing the required structural rigidity at reduced weight.
2Adaptability or versatility
If user interface elements such as protrusions, holes, or mounting structures are integrated into the display cover, then functionality is improved, but stress concentrations occur leading to early failure
Solution Approach 1:
The multilayer composite structure distributes stress across multiple materials with different mechanical properties. The polymer and ceramic coatings act as stress-distributing layers that prevent stress concentrations from propagating through the glass, thereby maintaining reliability even with integrated user interface elements.
Solution Approach 2:
The polymer and ceramic coatings serve as protective layers that cushion and distribute localized stresses before they can concentrate in the glass substrate. This beforehand cushioning prevents the initiation and propagation of cracks at stress concentration points.
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 results in a lightweight yet robust display cover that maintains structural integrity and optical quality, addressing the need for thinner and lighter designs while preventing early failure due to stress concentrations.
Implementation Method 1
applying a polymer coating to an ultra-thin glass sheet that corresponds in size to a display cover to form a composite layer
Implementation Method 2
vapor depositing a ceramic coating over at least one external ultra-thin glass sheet at an exterior surface of the multilayer composite display cover
Implementation Method 3
ionic exchange-strengthened glass
Data Source
AI summary
Methods for manufacturing a multilayer composite display cover include stacking a plurality of composite layers, each comprising an ultra-thin glass sheet covered in a polymer layer. After a cover glass sheet is placed on an exposed polymer layer, the composite layers may be bonded together. A ceramic coating may be applied to the external surfaces to increase hardness.