Opaque Metal Top Layer with Micro-Passages for Thin Displays
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Solution Overview
Problem
Conventional display devices face limitations in contrast range, display quality, mechanical stability, energy efficiency, and weight due to the use of glass in their construction, which also makes them prone to breakage and thick protective layers.
Innovation Solution
A method for producing a thin and essentially unbreakable display device by using a top layer comprising metal or opaque, non-light-reflecting materials with micro-passages that allow light to pass through, replacing traditional glass and enhancing mechanical stability and contrast.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a glass top layer is used in conventional display devices, then light transmission is achieved, but mechanical stability and breaking strength are limited
Solution Approach 1:
The patent changes the material parameter of the top layer from transparent glass to opaque metal or plastic materials. This fundamental material substitution maintains the protective function while dramatically improving mechanical stability and eliminating the brittleness inherent in glass, directly resolving the contradiction between strength and reliability
Solution Approach 2:
The patent employs composite structures where metal or plastic top layers are combined with the display components beneath. This composite approach allows the top layer to provide superior mechanical strength and durability while the underlying structure maintains display functionality, effectively resolving the strength-reliability contradiction
2Strength
If a thick protective glass layer is used, then mechanical protection is improved, but device thickness and weight increase
Solution Approach 1:
The patent changes the material properties of the top layer to metals or plastics that achieve superior mechanical protection at reduced thickness compared to glass. These materials provide equivalent or better protective function with significantly reduced dimensional requirements, resolving the contradiction between mechanical protection and device thickness
Solution Approach 2:
The patent uses metal or plastic top layers that can be manufactured thinner and more efficiently than glass, providing adequate protection without the excessive thickness requirements of traditional glass protective layers
3Strength
If an opaque top layer is used, then mechanical stability is improved, but light transmission is reduced
Solution Approach 1:
The patent employs metal or plastic top layers with micro-perforations or porous structures that allow light to pass through while maintaining the mechanical stability of the opaque material. The porous structure enables simultaneous achievement of mechanical strength and light transmission by providing pathways for light while preserving the structural integrity of the opaque material
Solution Approach 2:
The patent segments the top layer into regions with micro-perforations or openings that allow light transmission. This segmentation creates localized light pathways within the otherwise opaque material, resolving the contradiction between mechanical stability and light transmission by distributing light transmission functions across multiple discrete points
4Ease of manufacture
If conventional glass is used, then manufacturing is simplified, but contrast range and display quality are limited
Solution Approach 1:
The patent uses composite structures combining metal or plastic top layers with micro-perforation patterns and underlying display components. This composite design enables precise control over light transmission characteristics and contrast performance while maintaining manufacturing feasibility through established metal forming and perforation techniques
Data Source
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AI summary
The invention relates to a method for producing a thin and substantially fracture-resistant display device (1) comprising a display (2), wherein an upper layer (4) having a surface (O) facing an observer is arranged on light-emitting luminous surfaces (3) of the display (2), wherein micro-passages for transmitting generated light from the light-emitting luminous surfaces (3) of the display (2) are formed in the upper layer (4) and form micro-openings (A) in the surface (O) facing an observer, wherein a substantially planar surface (O) facing the observer is created on the upper layer (4), and wherein creating the substantially planar surface (O) comprises processing the surface (O) of the display device (1) facing the observer by means of a laser and/or by means of machining in order to produce the substantially planar surface (O). Furthermore, the invention relates to a display device.