Reinforced Support Layer Openings for Foldable Display Panels

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Solution Overview

Problem

There is a need for a method to readily fold a foldable flexible display device, particularly in manufacturing a display device with a foldable display panel.

Innovation Solution

A method involving forming an opening in a support layer with a reinforcing fiber, including preparing a digitizer and providing a display panel on the digitizer, with a folding region and non-folding regions, and creating openings of varying widths on opposite surfaces of the support layer to facilitate folding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a support layer with reinforcing fibers is used to maintain structural integrity, then strength is improved, but flexibility and ease of folding deteriorate

Engineering Contradiction:

Improvestructural integrityVSAvoidease of folding

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The support layer is segmented by forming openings (through-holes) within it, dividing the continuous fiber structure into sections. This segmentation reduces the overall rigidity while maintaining local strength, enabling the display device to be folded without breaking the support layer.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support layer has non-uniform structure with openings created at specific locations. The regions with openings have reduced strength and increased flexibility, while regions without openings maintain full structural integrity. This local variation in quality allows the device to fold at intended locations while maintaining strength elsewhere.

Inventive Principle:

Principle #3Local quality

2Ease of operation

If openings are formed in the support layer to enable folding, then ease of folding is improved, but manufacturing precision requirements worsen

Engineering Contradiction:

Improveease of foldingVSAvoidopening dimensions

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The mechanical drilling or cutting process is replaced with laser processing to form openings in the support layer. Laser processing offers higher precision, cleaner edges, and better control over opening dimensions, reducing manufacturing variability and improving overall manufacturing precision despite the complexity of the opening geometry.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables the easy folding of flexible display devices by providing structural support and alignment for the display panel, enhancing user convenience and durability.

Implementation Method 1

forming an opening penetrating the preliminary support layer by providing a laser or an abrasive agent to the one surface of the preliminary support layer

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

forming an opening penetrating the preliminary support layer by providing a laser or an abrasive agent to the one surface of the preliminary support layer

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS12535860B2Method for manufacturing display device, display device manufactured thereby, and electronic device including the same

Publication Date: 2026.01.27 SAMSUNG DISPLAY CO LTD

AI summary

A method for manufacturing a display device may include providing a support layer and a display panel on a digitizer. The display panel may include a folding region that is folded with reference to a folding axis extending in a first direction. The providing of the support layer may include forming an opening penetrating the preliminary support layer by providing a laser or an abrasive agent to one surface of the preliminary support layer. A first width of the opening on the one surface in a second direction and a second width of the opening on another surface in a second direction may be different from each other, and the second direction is perpendicular to the first direction.