Overmolded Segmented Display Borders for Curved, Low-Stress Covers
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Solution Overview
Problem
Conventional electronic devices with flat display covers and housing surfaces have abrupt corners that are uncomfortable to hold and applying a curved border material introduces stress, leading to potential damage during manufacturing and use.
Innovation Solution
A segmented border portion is applied to the electronic device, composed of a first and second material, with interlocking segments to reduce stress and provide a curved appearance, allowing larger and thinner body panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a second border material is applied around the display cover to create a smooth, curved border, then the comfort and aesthetics of the device are improved, but stress is introduced to the display cover during manufacturing and use, leading to potential damage
Solution Approach 1:
The border portion is divided into multiple segments instead of being a continuous piece. Each segment can move independently, allowing the border to accommodate dimensional changes of the display cover without transmitting excessive stress, thereby preventing damage while maintaining comfort
Solution Approach 2:
The border segments are designed with specific material properties and geometric parameters that allow them to flex and adapt to the display cover's dimensional changes. The segments can change their effective length and curvature to match the display cover's expansion or contraction, reducing stress concentration
2Weight of moving object
If the bezel around the display is reduced to produce smaller and lighter electronic devices, then the device size and weight are improved, but the display cover becomes more susceptible to damage from stress during manufacturing and use
Solution Approach 1:
The segmented border acts as a buffer that isolates the display cover from stress concentrations. By dividing the border into separate segments with gaps between them, the system allows the display cover to dimensional change freely without being constrained by a continuous rigid border, thereby preventing damage in lighter devices with reduced bezels
3Shape
If a continuous border material is applied around the display cover, then a smooth curved appearance is achieved, but compressive forces are introduced that can damage the display cover
Solution Approach 1:
The border is segmented into multiple pieces that collectively form a curved appearance. The gaps between segments prevent the transmission of compressive forces that would occur in a continuous border, while the segments themselves maintain the desired curved shape for aesthetic purposes
Solution Approach 2:
The border segments are designed to be dynamic rather than static, allowing them to adjust their position and shape in response to forces from the display cover. This dynamic capability allows the border to maintain its curved appearance while accommodating dimensional changes without generating damaging compressive forces
Data Source
AI summary
An electronic device includes a display with a glass planar portion and a second material position at an outer edge of the glass planar portion. The glass planar portion defines a majority of a display surface of the display, and the second material is molded to the outer edge of the glass planar portion and defines at least part of a border portion. The second material is curved in a direction perpendicular to the display surface. The second material is composed of a first plurality of segments and a second plurality of segments. Each segment of the second plurality of segments is interposed between adjacent segments of the first plurality of segments, and the first plurality of segments interlock with the second plurality of segments.