Support Film Thickness Variation for Display Panel Crack Prevention
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Solution Overview
Problem
Display devices face issues with bubble formation and cracking in the adhesive member between the cover window and the display panel, particularly in bent areas, due to stress and thickness variations of the support film.
Innovation Solution
A display device design where a support film with varying thickness is used, with a thicker film in the flat area and a thinner film in the bent areas, to reduce bubble size and prevent cracks, while maintaining handleability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a uniform thickness support film is used across the entire display panel, then the manufacturing process is simple, but bubble formation occurs in bent areas and cracks develop in the adhesive member
Solution Approach 1:
The support film is designed with non-uniform thickness, featuring a first thickness in flat areas and a second thickness (greater than the first) in bent areas. This local variation in thickness allows the film to accommodate curvature changes without creating bubbles or cracks in the adhesive member, while maintaining ease of manufacture through a systematic thickness variation approach
2Reliability
If a thicker support film is used in bent areas, then bubble size is reduced and cracks are prevented, but the overall device complexity increases
Solution Approach 1:
The support film implements localized thickness adjustment where bent areas have a greater thickness than flat areas. This local quality variation specifically targets the bent regions to prevent cracks and reduce bubble size without unnecessarily increasing the complexity of the entire film structure
Solution Approach 2:
The invention changes the physical parameter of thickness along the length of the support film, transitioning from a first thickness in flat areas to a second (greater) thickness in bent areas. This parameter change allows the film to accommodate mechanical stress in bent regions without causing cracks or excessive bubble formation
Data Source
AI summary
A display device in which a flat area, a first bent area disposed on a side in a first direction of the flat area, and a second bent area disposed on a side in a direction opposite to the first direction of the flat portion are defined includes a display panel including portions respectively overlapping the flat area, the first bent area, the second bent area, each of the portions of the display panel includes a first surface and a second surface opposite to the first surface, and a support film disposed on the second surface of the display panel. A portion of the support film overlapping the flat area has a first thickness. A portion of the support film overlapping each of the first bent area and the second bent area has a second thickness smaller than the first thickness.