Variable-Modulus Support Structure for OLED Display Lamination
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Solution Overview
Problem
The lamination process for double-sided OLED screens with high screen-to-body ratios faces challenges such as warping, bulging, and difficulty in aligning the cover plate with the display panel, leading to gaps, bubbles, and wrinkles.
Innovation Solution
A display device design featuring a cover plate with planar and curved portions enclosing an accommodation space, and a support plate with varying modulus support portions, combined with a lamination system using a carrier film, clamp, slider, and mechanical arm to ensure precise lamination without warping or bulging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a double-sided OLED screen with high screen-to-body ratio is designed, then the screen-to-body ratio is improved, but the lamination process becomes difficult causing warping and bulging
Solution Approach 1:
The support plate is segmented into multiple portions with different moduli: a first support portion with high modulus for rigid support, a second support portion with intermediate modulus for transition, and a third support portion with low modulus for flexibility. This segmentation allows each portion to perform its specific function in the lamination process, preventing warping and bulging while maintaining high screen-to-body ratio.
Solution Approach 2:
Different regions of the support plate are assigned different mechanical properties (modulus values) according to their specific functional requirements. The first support portion has high modulus for structural stability, the second has intermediate modulus for gradual transition, and the third has low modulus for adapting to curved surfaces. This local quality differentiation resolves the lamination difficulty caused by uniform structure.
2Strength
If the cover plate is laminated to the display panel, then the structural integrity is improved, but warping and bulging occur during the process
Solution Approach 1:
The support plate is prepared in advance with a specific multi-region modulus structure before the lamination process begins. This preliminary design ensures that during lamination, the different portions of the support plate provide appropriate support to prevent warping and bulging, maintaining flatness throughout the process while achieving strong bonding.
Solution Approach 2:
The modulus parameter of the support plate is changed across different regions to optimize lamination performance. By creating a gradient of modulus values from high to low across the support plate, the system can maintain structural integrity during bonding while preventing deformation, thus resolving the contradiction between strength and flatness.
3Device complexity
If a uniform support plate is used, then the device complexity is reduced, but the lamination precision deteriorates causing gaps and bubbles
Solution Approach 1:
Instead of using a uniform support plate, the invention segments the support plate into multiple functional regions with different moduli. This segmentation, while increasing structural complexity, dramatically improves lamination precision by providing targeted support in different areas, preventing gaps and bubbles that would occur with a uniform structure.
Solution Approach 2:
The support plate is designed with local quality variations where different regions have different mechanical properties tailored to their specific functions. This local differentiation improves lamination alignment and prevents defects, demonstrating that increased structural complexity is necessary to achieve the required manufacturing precision.
Data Source
AI summary
A display apparatus, an attaching system and an attaching method. The display apparatus comprises a cover plate (2), a display panel (1) and a supporting plate (3). The cover plate (2) comprises a first flat surface portion (21), a second flat surface portion (22) and a first curved surface portion (23), wherein the first curved surface portion (23) is smoothly connected between the first flat surface portion (21) and the second flat surface portion (22); the second flat surface portion (22) is parallel to the first flat surface portion (21); the first curved surface portion (23) extends in a first direction; an orthographic projection of the first curved surface portion (23) on a first reference plane is arc-shaped; the first reference plane is perpendicular to an extension direction of the first curved surface portion (23); and an accommodating space is formed by means of the enclosure of the first flat surface portion (21), the second flat surface portion (22) and the first curved surface portion (23). The display panel (1) is arranged in the accommodating space. The supporting plate (3) comprises a first straight supporting portion (3a), a first cambered surface supporting portion (3b) and a second straight supporting portion (3c), which are sequentially connected; the modulus of the first cambered surface supporting portion (3b) is smaller than that of the first straight supporting portion (3a) and is also smaller than that of the second straight supporting portion (3c); the first straight supporting portion (3a) is attached to the side of the display panel (1) away from the first flat surface portion (21); the first cambered surface supporting portion (3b) is attached to the side of the display panel (1) away from the first curved surface portion (23); and the second straight supporting portion (3c) is attached to the side of the display panel (1) away from the second flat surface portion (22). The supporting plate (3) has enough strength to support the display panel (1), and the supporting plate (3) has enough flexibility so as not to be prone to warping and bulging when being bent, thereby preventing the display panel from warping and bulging.