Polarization Unit Step Difference for Display Bending
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Solution Overview
Problem
Existing display devices face challenges in manufacturing efficiency and cost due to complex processes and the need for separate lamination steps, especially when incorporating bending areas and protective layers, which can lead to visibility issues with bent portions and increased production costs.
Innovation Solution
A display device design featuring a polarization unit with a defined step difference that extends to cover bending areas, combined with a coating window made of resin material directly applied to the polarization unit, simplifies the manufacturing process and reduces costs by preventing external visibility of bent portions and eliminating the need for additional lamination steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate lamination process is used to attach the polarization unit to the bending protective layer, then the polarization unit can be securely fixed, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent merges the polarization unit and bending protective layer into a single integrated structure where the polarization unit is directly formed on the bending protective layer without requiring separate lamination. This integration eliminates the need for additional attachment processes while maintaining secure fixation, thereby reducing manufacturing complexity and costs while preserving attachment reliability.
Solution Approach 2:
The bending protective layer serves multiple functions: it protects the bending area of the display panel and simultaneously serves as the base layer for forming the polarization unit. This multi-functionality eliminates the need for separate lamination processes, reducing manufacturing steps and costs while maintaining secure attachment of the polarization unit.
2Ease of manufacture
If the polarization unit does not extend to cover the bending area, then the manufacturing process is simpler, but the bent portions become visible from the front surface
Solution Approach 1:
The polarization unit is segmented into different regions with different thicknesses: a first polarization portion with greater thickness on the non-bending area and a second polarization portion with smaller thickness on the bending protective layer. This segmentation allows the polarization unit to extend over the bending area to conceal bent portions while maintaining manufacturing feasibility through the thickness variation.
Solution Approach 2:
The polarization unit exhibits local quality variation through its stepped structure, where different regions have different thicknesses optimized for their specific functions. The thicker first polarization portion provides adequate coverage on the non-bending area, while the thinner second polarization portion extends over the bending protective layer to conceal bent portions without requiring excessive material or complex manufacturing.
3Ease of manufacture
If the polarization unit is made with uniform thickness, then the manufacturing process is simpler, but it cannot accommodate the step difference required to correspond to the bending protective layer
Solution Approach 1:
The bending protective layer is formed first as a preliminary structure before forming the polarization unit. This preliminary action creates a predefined surface topology with the bending protective layer that guides the subsequent formation of the polarization unit with the required step difference, making it easier to achieve precise thickness variations without complex manufacturing processes.
Solution Approach 2:
The patent solves the thickness variation requirement by utilizing the vertical dimension to create a stepped structure. The polarization unit transitions from a single-layer uniform thickness design to a multi-level structure with different thicknesses in different regions, accommodating the step difference requirement while maintaining manufacturing feasibility through vertical layering rather than horizontal complexity.
Data Source
AI summary
A display device includes a display panel having a non-bending area and a bending area extending from an end of the non-bending area, wherein the display panel includes a display panel bendable portion, a bending protective layer disposed on the display panel and including a bending protective layer bent portion being bendable with the bending area, a polarization unit disposed on the display panel, partially disposed on the bending protective layer, and defining a step difference which corresponds to the bending protective layer, and a coating window disposed directly on the polarization unit and including a resin material. The polarization unit overlaps the bending area and the non-bending area. The polarization unit covers the display panel bendable portion.