Polymer Layer Segmentation for Display Pad Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The reliability of connections between electronic components in display devices is compromised due to misalignment caused by stretching substrates during the heat-pressing process, leading to reduced performance and efficiency.
Innovation Solution
A display device design featuring a polymer layer with non-bending and bending areas, where signal and connection pad groups are strategically arranged with openings to distribute stress and prevent deformation, along with a flexible circuit board and protection layers to maintain the bent state and reduce bezel size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If substrates are heat-pressed to connect electronic components, then electrical connections are established, but the substrates stretch causing pad misalignment and reducing connection reliability
Solution Approach 1:
The substrate is divided into multiple regions with different properties: a first substrate region and a second substrate region. The first region is designed to resist stretching during heat-pressing, while the second region allows controlled deformation. This segmentation enables the substrate to maintain pad alignment precision while still establishing electrical connections through heat-pressing.
Solution Approach 2:
Different regions of the substrate are given different mechanical properties. The first substrate region has properties that prevent stretching and maintain dimensional stability for precise pad alignment, while the second region has properties that accommodate deformation. This local differentiation allows the substrate to simultaneously achieve connection reliability and manufacturing precision in different areas.
2Reliability
If the polymer layer is made fully rigid to prevent deformation, then connection reliability improves, but the bezel area increases and flexibility is lost
Solution Approach 1:
The polymer layer is segmented into a first substrate region with rigid, non-bending properties and a second substrate region with flexible, bendable properties. The first region maintains connection reliability by resisting deformation, while the second region reduces bezel area by allowing controlled bending. This segmentation enables the polymer layer to simultaneously achieve reliability and compactness.
Solution Approach 2:
The polymer layer exhibits local quality differences where the first substrate region has high rigidity to prevent pad misalignment and maintain connection reliability, while the second substrate region has lower rigidity to enable bending and reduce overall device size. This localized property differentiation resolves the contradiction between reliability and compactness.
3Stability of the object's composition
If openings are added to the polymer layer to distribute stress, then deformation is reduced, but manufacturing complexity increases
Solution Approach 1:
The polymer layer is segmented into functional regions (first and second substrate regions) with distinct mechanical properties. This segmentation inherently creates zones of different stress distribution, reducing the need for additional complex stress-management features while maintaining polymer layer stability during heat-pressing and bending operations.
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 design enhances the reliability of connections, reduces deformation, and minimizes the bezel area by effectively managing stress and maintaining the bent state of the polymer layer, thereby improving the overall performance and appearance of the display device.
Implementation Method 1
a polymer layer including a first non-bending area, a second non-bending area that overlaps the first non-bending area when viewed in a plan view, and a bending area arranged between the first non-bending area and the second non-bending area
Data Source
AI summary
A display device includes a display substrate comprising a polymer layer including a first non-bending area, a second non-bending area that overlaps the first non-bending area when viewed in a plan view, and a bending area arranged between the first non-bending area and the second non-bending area. A display element layer is disposed on the polymer layer. A plurality of signal pad groups is disposed in the second non-bending area and is configured to be electrically connected to the display element layer. An upper substrate is disposed on a top surface of the display substrate. A flexible circuit board comprising a plurality of connection pad groups is arranged in correspondence to the signal pad groups. An area of the upper substrate is larger than an area of the display substrate when viewed in a plan view.