Segmented Display Border Overmolding to Reduce Glass Stress
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Solution Overview
Problem
Conventional electronic devices with flat display covers and reduced bezels face manufacturing stress and potential damage due to abrupt corners and material contraction, leading to increased risk of fractures and breakage.
Innovation Solution
A segmented border portion is applied to a planar body panel in two stages, using materials with different properties to alleviate stress from material contraction during cooling and curing, enhancing durability and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a continuous border material is applied around the display cover to create curved edges, then aesthetic appearance and user comfort are improved, but stress and potential damage to the display cover increase due to material contraction during manufacturing and device lifetime
Solution Approach 1:
The border is divided into multiple discrete segments rather than being continuous. Each segment is separately positioned and attached to the display cover, allowing independent stress management. The segments create gaps that prevent continuous stress transmission around the entire display cover perimeter, thereby reducing the risk of cracks and damage while maintaining the curved aesthetic appearance.
Solution Approach 2:
Different regions of the border are treated differently through segmentation. Specific high-stress areas (such as corners and edges) can have different segment configurations, spacing, or attachment methods compared to other regions. This allows optimization of stress distribution locally while maintaining overall curved appearance, addressing the specific vulnerability points where cracks are most likely to initiate.
2Weight of moving object
If the bezel is reduced to make electronic devices smaller and lighter, then device size and weight are improved, but the risk of damage to the display cover increases due to reduced structural support
Solution Approach 1:
The segmented border structure provides structural support through distributed attachment points rather than requiring a continuous thick bezel. Each segment acts as an independent support element, collectively providing sufficient mechanical reinforcement to protect the display cover even when the overall bezel width is minimized. This enables lightweight design while maintaining display cover integrity.
3Ease of operation
If a second border material is applied to create smooth curved borders, then user comfort and aesthetics are improved, but manufacturing complexity and stress introduction increase
Solution Approach 1:
The border is implemented as separate segments that can be manufactured independently and then positioned around the display cover. This segmentation simplifies the manufacturing process by allowing parallel production of border segments, easier handling and positioning, and reduced complexity in the molding and assembly processes compared to creating a single continuous curved border structure.
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
The segmented border portion reduces compressive forces on the body panel, allowing for larger and thinner designs with improved comfort and reduced risk of fractures, while maintaining a seamless appearance.
Implementation Method 1
contraction of the second material related to cooling and/or curing of the second material
Data Source
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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.