Strengthened Structural Module with Conformal Coating
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Solution Overview
Problem
Existing structural modules for displays, particularly those using glass substrates, face challenges in achieving high mechanical robustness and strength, especially as display sizes increase, due to the mechanical weakness of thin glass sheets which are prone to rupture under environmental disturbances.
Innovation Solution
A strengthened structural module is created by placing a spacer element between two glass substrates to form a closed space, with a conformal coating applied around the outside surfaces, including the spacer, to enhance the module's strength and sealing, using methods like Atomic Layer Deposition (ALD) for a thin-film coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a thin glass sheet is used to reduce weight and improve optical quality, then the weight and optical properties are improved, but the mechanical strength and resistance to rupture are reduced
Solution Approach 1:
The patent applies composite materials by combining a thin glass sheet with a polymer coating layer to create a strengthened structural module. The polymer coating acts as a reinforcement layer that compensates for the mechanical weakness of the thin glass substrate, allowing the module to achieve both low weight and high strength simultaneously. This is evident in the description of the structural module comprising a glass substrate with a polymer coating that provides mechanical reinforcement.
2Illumination intensity
If a single homogeneous glass sheet is used to ensure optical uniformity, then the optical quality is improved, but the manufacturing complexity and difficulty of obtaining large sizes are increased
Solution Approach 1:
The patent applies segmentation by dividing the structural module into multiple components: a glass substrate and a separate polymer coating layer. This allows the glass substrate to be manufactured separately with optimized optical properties, while the polymer coating is applied subsequently to provide mechanical strength. The modular structure simplifies manufacturing and enables larger sizes compared to requiring a single large homogeneous glass sheet.
Solution Approach 2:
The patent uses composite materials to combine the optical advantages of glass with the mechanical advantages of polymer materials. The glass substrate provides excellent optical uniformity and low light absorption, while the polymer coating layer provides mechanical reinforcement. This composite structure resolves the contradiction between optical quality and manufacturing complexity by allowing separate optimization of each component.
3Ease of manufacture
If no coating is applied to maintain simplicity, then the manufacturing process is simpler, but the mechanical robustness and strength of the module are reduced
Solution Approach 1:
The patent applies flexible shells and thin films by using a polymer coating layer that is deposited as a thin film on the glass substrate. This thin polymer film provides significant mechanical reinforcement to the thin glass substrate while adding minimal weight and complexity to the manufacturing process. The polymer coating acts as a flexible protective shell that enhances the overall mechanical robustness of the structural module.
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 conformal coating significantly increases the flexural strength and Weibull modulus of the module, providing improved mechanical robustness and sealing, allowing for efficient sealing of sensitive components and reducing gas diffusion, while maintaining transparency and versatility for use in displays and touch panels.
Implementation Method 1
using methods like Atomic Layer Deposition (ALD) for a thin-film coating
Implementation Method 2
The module comprises a coating surrounding the module around the outside of the module, the coating being arranged conformally on the glass substrate, on the second substrate and on the at least one spacer element, on the surfaces facing the outside of the module, for increasing the strength of the module
Data Source
AI summary
A strengthened structural module (2) and a method for fabricating a strengthened structural module (2). The module comprises an essentially planar glass substrate (1), an essentially planar second substrate (3), and at least one spacer element (5) in between the glass substrate (1) and the second substrate (3). The at least one spacer element (5) keeps the glass substrate (1) and the second substrate (3) separated from each other from the edges of the two substrates and defines a space (7) in between the two substrates in the inside of the module. The module comprises a coating (9) surrounding the module around the outside of the module. The coating (9) is arranged conformally on the surfaces facing the outside of the module, for increasing the strength of the module.