Multi-Layer Resin Window Member for Display Impact Resistance
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Solution Overview
Problem
Display devices face challenges in achieving both impact resistance and cost-effective manufacturing with existing window members, as they often suffer from scratch marks and breakage due to external impacts, and current manufacturing processes are complex and costly.
Innovation Solution
A window member with a multi-layer structure comprising a first resin layer and a second resin layer, where the second resin layer has higher hardness and thickness than the first, and an optical clear adhesive layer, along with a bezel layer, to enhance impact resistance and simplify the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layer window member is used, then the manufacturing process is simple, but the impact resistance is poor and scratch marks occur easily
Solution Approach 1:
The window member is constructed as a composite structure with a first resin layer (polycarbonate or polyethylene terephthalate) and a second resin layer (acrylic-based resin such as polymethyl methacrylate). The first layer provides impact resistance while the second layer provides hardness and scratch resistance, achieving both durability requirements through material composition rather than process complexity.
2Ease of manufacture
If existing manufacturing processes are used, then production cost is reduced, but defect rate increases due to complex processes
Solution Approach 1:
The manufacturing method pre-forms the first resin layer with a recessed region matching the three-dimensional shape required, then fills this pre-prepared space with the second resin material. This preliminary preparation eliminates the need for complex post-forming operations and reduces manufacturing defects while maintaining cost-effectiveness.
Solution Approach 2:
The window member is divided into two separately manufactured resin layers that are subsequently bonded together. This segmentation allows each layer to be optimized independently for its specific function (impact resistance for the first layer, hardness for the second layer) while simplifying the overall manufacturing process through modular construction.
3Strength
If the second resin layer has higher hardness, then surface hardness and scratch resistance improve, but the overall structure may become more brittle
Solution Approach 1:
The window member employs local quality differentiation where the second resin layer (acrylic-based) provides localized surface hardness and scratch resistance where needed, while the first resin layer (polycarbonate or polyethylene terephthalate) maintains overall structural integrity and impact resistance. Each material is positioned to perform its specific function optimally without compromising the whole structure.
Data Source
AI summary
A display device includes a window member and a display module coupled to the window member. The window member includes a first resin layer and a second resin layer. The first resin layer is on the display module and has a first elongation, a first thickness, and a first hardness. The second resin layer is on the display module and the first resin layer and has a second elongation smaller than the first elongation, a second thickness greater than the first thickness, and a second hardness greater than the first hardness.