Shape-Adaptive Display Assembly With Rigid-Flexible Segmentation
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Solution Overview
Problem
Existing display technologies struggle to create shape-adaptive displays that can bend and flex to conform to various enclosures, as pixel emitters and backplane circuitry are typically fabricated on rigid substrates, limiting their flexibility and adaptability.
Innovation Solution
The development of shape-adaptive display assemblies that incorporate a rigid segment for structural support and a flexible segment for adaptability, using a pattern of conductive material, integrated circuits, and pixel emitters distributed across both segments, allowing for the removal of rigid substrates to achieve flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pixel emitters and backplane circuitry are fabricated on rigid substrates, then manufacturing precision and structural support are improved, but flexibility and shape adaptability deteriorate
Solution Approach 1:
The display assembly is divided into a rigid segment containing the integrated circuit and a flexible segment containing the pixel emitters. This segmentation allows each part to have optimal properties: the rigid segment provides structural support and precise circuit integration, while the flexible segment enables shape adaptation and bending without breaking the pixel emitters or conductive material patterns.
Solution Approach 2:
The integrated circuit is extracted from the flexible substrate and placed on a separate rigid substrate. This extraction resolves the contradiction by allowing the circuit to be fabricated with high precision on a rigid surface while the pixel emitters remain on a flexible substrate that can bend and adapt to different shapes.
2Strength
If rigid substrates are used for structural support, then strength and stability are improved, but flexibility and ability to conform to enclosures deteriorate
Solution Approach 1:
The display assembly is segmented into rigid and flexible portions. The rigid segment provides necessary structural support and stability for the integrated circuit, while the flexible segment enables bending and conforming to various enclosure shapes. This segmentation resolves the contradiction by distributing different functional requirements to appropriate material segments.
Solution Approach 2:
Different segments of the display assembly have different mechanical properties tailored to their specific functions. The rigid segment has high strength and stability for supporting circuits, while the flexible segment has high flexibility for shape adaptation. This local differentiation of material properties resolves the contradiction between overall strength and flexibility.
3Adaptability or versatility
If the entire display assembly is made flexible, then shape adaptability is improved, but manufacturing precision and structural support deteriorate
Solution Approach 1:
The integrated circuit is extracted from the flexible substrate and manufactured separately on a rigid substrate with high precision fabrication processes. This extraction allows the circuit to be fabricated with optimal precision while the pixel emitters remain on the flexible substrate, resolving the contradiction between flexibility and manufacturing precision.
Solution Approach 2:
The display assembly is segmented into a rigid segment for high-precision circuit fabrication and a flexible segment for shape adaptation. This segmentation allows each segment to be optimized for its specific function without compromising the other.
4Adaptability or versatility
If rigid substrates are removed to achieve flexibility, then shape adaptability is improved, but structural support and stability deteriorate
Solution Approach 1:
The display assembly is segmented into rigid and flexible portions, each providing different mechanical properties. The rigid segment maintains structural stability for the integrated circuit while the flexible segment provides shape adaptability. This segmentation resolves the contradiction by distributing structural and flexibility requirements to appropriate segments.
Solution Approach 2:
The display assembly uses a composite structure combining rigid and flexible materials in specific segments. This composite approach allows the assembly to have both the structural stability of rigid materials and the flexibility of flexible materials, resolving the contradiction between these opposing requirements.
Data Source
AI summary
Shape-adaptive display assemblies are described herein, along with methods for their fabrication. One example method for fabricating a display assembly with a rigid segment and a flexible segment includes: depositing a pattern of conductive material onto a first substrate; coupling an integrated circuit to a first side of the pattern of conductive material, the integrated circuit disposed on the rigid segment without extending to the flexible segment; depositing a molding layer onto the first side of the pattern of conductive material, the molding layer configured to encapsulate the integrated circuit and to extend over the rigid segment and the flexible segment; bonding a second substrate to the molding layer and removing the first substrate to expose a second side of the pattern of conductive material; and coupling a plurality of pixel emitters to the second side of the pattern of conductive material and removing the second substrate.