Tapered Supporting Substrates for Flexible Display Stress Management

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Solution Overview

Problem

Conventional display devices face challenges in manufacturing efficiency and yield due to issues with bending and stress distribution during the accommodation process, particularly in flexible display panels where the bending of substrates can lead to cracking or peeling of layers, and residual formation during cutting processes.

Innovation Solution

The implementation of a display device structure featuring tapered supporting substrates and a resin layer with specific thickness and refractive index profiles, along with a groove portion between the substrates, to manage stress and prevent cracking by optimizing the cutting process with laser beams and ensuring even refractive changes, thereby suppressing residual formation and improving yield.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the substrate is bent to accommodate the display device in an electronic device, then the frame can be narrowed and the display device can be integrated, but the bending can lead to cracking or peeling of layers and reduce manufacturing yield

Engineering Contradiction:

Improveintegration into electronic deviceVSAvoidmanufacturing yield

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The supporting substrate is divided into a first supporting substrate and a second supporting substrate that are spaced apart, creating a segmented structure that allows controlled bending while maintaining overall support integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first and second supporting substrates are formed with different thickness profiles (tapered shapes narrowing toward opposing side surfaces), creating local variations in mechanical properties that optimize stress distribution during bending

Inventive Principle:

Principle #3Local quality

2Productivity

If conventional cutting processes are used to manufacture display devices, then production can proceed efficiently, but residuals are formed during cutting which reduce manufacturing yield

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidcutting precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The thickness of the supporting substrates is varied according to specific parameters (tapered profiles), which changes the mechanical properties and stress distribution during cutting, preventing residual formation while maintaining manufacturing efficiency

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If the supporting substrates are made with uniform thickness, then manufacturing is simpler, but stress distribution during bending is uneven leading to cracking and peeling

Engineering Contradiction:

Improvesubstrate fabrication simplicityVSAvoidstress resistance during bending

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The supporting substrates feature localized thickness variations with tapered profiles, where the thickness changes gradually from the thickest portion to the thinnest portion, optimizing stress distribution at different locations without requiring complex manufacturing processes

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The thickness variation is introduced as a gradual dimensional change (tapered profile) rather than abrupt steps, creating a smooth transition that prevents stress concentration while maintaining manufacturing feasibility

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

This configuration effectively suppresses the occurrence of residuals and peeling, enhances manufacturing yield, and maintains the integrity of the display panel during bending, ensuring reliable performance and reduced operational costs.

Implementation Method 1

a resin layer extending along a first direction on the insulating substrate and having a third thickness less than the second thickness at the first position; the resin layer having a refractive index different from that of the insulating substrate

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentUS10840463B2Display device

Publication Date: 2020.11.17 MAGNOLIA WHITE CORP

AI summary

According to one embodiment, a display device includes an insulating substrate including a first main surface, a first supporting substrate adhered to the first main surface of the insulating substrate, and a second supporting substrate spaced from the first supporting substrate and adhered to the first main surface of the insulating substrate, and the first supporting substrate includes a first side surface opposing the second supporting substrate, the second supporting substrate includes a second side surface opposing the first supporting substrate, the first supporting substrate is formed into a tapered shape which narrows toward the first side surface, and the second supporting substrate is formed into a tapered shape which narrows toward the second side surface.