The mobile nature of portable devices, such as smartphones, tablets, portable media players, personal computers, and cameras, makes these devices particularly vulnerable to accidental dropping on hard surfaces, such as the ground. These devices typically incorporate cover glasses, which may become damaged upon impact with hard surfaces. In many of these devices, the cover glasses function as display covers, and may incorporate touch functionality, such that use of the devices is negatively impacted when the cover glasses are damaged.
There are two major failure modes of cover glass when the associated portable device is dropped on a hard surface. One of the modes is flexure failure, which is caused by bending of the glass when the device is subjected to dynamic load from impact with the hard surface. The other mode is sharp contact failure, which is caused by introduction of damage to the glass surface. Impact of the glass with rough hard surfaces, such as asphalt, granite, etc., can result in sharp indentations in the glass surface. These indentations become failure sites in the glass surface from which cracks may develop and propagate.
Glass can be made more resistant to flexure failure by ion-exchange technique, which involves inducing compressive stress in the glass surface. However, the ion-exchanged glass will still be vulnerable to dynamic sharp contact, owing to the high stress concentration caused by local indentations in the glass from the sharp contact.
It has been a continuous effort for the glass makers and handheld device manufacturers to improve the resistance of handheld devices to sharp contact failure. Solutions range from coatings on the cover glass to bezels that prevent the cover glass from touching the hard surface directly when the device drops on the hard surface. However, due to the constraints of aesthetic and functional requirements, it is very difficult to completely prevent the cover glass from touching the hard surface.
The invention relates to a method of reducing damage to the cover glass of a portable electronic device due to impact of the device on a hard surface.
In one illustrative embodiment, a portable electronic device includes a device body having a cavity in which a plurality of device structures is contained, one of the device structures being a display module. A cover glass is disposed at an opening of the device body such that at least one of the plurality of device structures underlies the cover glass. An energy absorbing interlayer is disposed between the cover glass and the at least one underlying device structure. The energy absorbing interlayer has a stiffness that is lower than a stiffness of the cover glass.
In another illustrative embodiment, a cover glass article for a portable electronic device includes a cover glass shaped to at least partially cover an opening of a device body of the portable electronic device. The cover glass is made of a glass or glass-ceramic material having at least one surface under a compressive stress of at least 200 MPa and a compressively stressed layer with a depth of layer of at least 1% of a thickness of the material. An energy absorbing layer is formed on a surface of the cover glass. The energy absorbing layer has a stiffness lower than a stiffness of the cover glass.
It is to be understood that both the foregoing general description and the following detailed description are exemplary of the invention and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments of the invention and together with the description serve to explain the principles and operation of the invention.
The following is a description of the figures in the accompanying drawings. The figures are not necessarily to scale, and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
A method of protecting a cover glass on a portable device, particularly of the handheld type, from damage when the device falls on a hard surface, such as the ground, involves disposing a thin energy absorbing interlayer between the cover glass and underlying device structures. The energy absorbing interlayer will increase the resistance of the cover glass to sharp contact failure due to impact of the device with the hard surface. According to simulation studies of handheld devices, the interlayer material underneath the cover glass plays an important role in the dynamic contact force between the cover glass and the hard surface, which is believed to be strongly related to glass damage due to dynamic sharp indentation. It has been observed that the lower the stiffness of the energy absorbing interlayer is, the lower the contact force between the cover glass and the hard surface, thus the lower the probability of glass failure under sharp indentation. Therefore, within the design space of the handheld device system, reducing the rigidity of the interlayer material underneath the cover glass will reduce the glass damage.
In one embodiment, the cover glass 18 is made of a glass or glass-ceramic material. In one embodiment, for improved resistance to scratching and flexure failure, the cover glass 18 may preferably be made of a glass or glass-ceramic material that has been chemically strengthened. In one embodiment, the cover glass 18 may be made of a glass or glass-ceramic material that has been chemically strengthened to have at least one surface under a compressive stress of at least 200 MPa and a compressively stressed layer with a depth of layer (DOL) of at least 1% of the material thickness. In another embodiment, the cover glass 18 may be made of a glass or glass-ceramic material that has been chemically strengthened to have at least one surface under a compressive stress of at least 700 MPa and a compressively stressed layer with a DOL of at least 1% of the material thickness. GORILLA® glass, available from Corning Incorporated, New York, is an example of a class of glasses that may be used for the cover glass 18. Other materials suitable for making the cover glass 18 may be hard plastics or ceramics.
The cover glass 18 may have a 2D or 3D shape, such as flat shape, dish shape, or sled shape, adapted for at least partially covering the front opening 16 of the device body 14. In one embodiment, the cover glass 18 may be transparent to allow viewing of the images processed by the underlying display module 26. Typically, the cover glass 18 will have a uniform thickness. For portable electronic devices where thinness is typically important, the thickness of the cover glass 18 may be between 50 microns and 2.0 mm.
In one embodiment, the portable electronic device 10 further includes one or more energy absorbing interlayers disposed between the cover glass 18 and selected underlying device structures. The particular underlying device structures will depend on the configuration or design of the portable electronic device 10. The energy absorbing interlayer(s) will absorb impact energy from the cover glass 18 during a drop event, thereby protecting the cover glass 18 from damage.
In one embodiment, as shown in
The energy absorbing interlayer portions 30A1, 30B1 may have the same or different energy absorbing characteristics.
In some embodiments, it may be convenient to use the back surface 19 of the cover glass 18 as a carrier for the energy absorbing interlayer 30. That is, the energy absorbing interlayer 30 may be formed on, or applied to, the back surface 19 of the cover glass 18 such that when the cover glass 18 is disposed at the front opening 16 of the device body 14, the energy absorbing interlayer 30 will be in the appropriate position between the cover glass 18 and the desired underlying device structure(s).
Each energy absorbing interlayer 30 is sandwiched between the cover glass 18 and one or more device structures underlying the cover glass 18, i.e., underlying device structure(s). In one embodiment, the energy absorbing interlayer 30 is “soft” relative to the adjacent cover glass 18. The energy absorbing interlayer 30 is preferably also soft relative to each adjacent underlying device structure. Stiffness may be used as a measure of softness. Therefore, the energy absorbing layer 30 may be considered as softer than a part if it has a stiffness that is lower than that of the part. Also, Young's modulus, or elastic modulus, may provide a measure of stiffness. Therefore, the energy absorbing layer 30 may be considered as softer than a part if it has a Young's modulus that is smaller than that of the part. In one embodiment, the energy absorbing interlayer 30 has a Young's modulus that is at least 10 times smaller than the Young's modulus of the cover glass 18. In another embodiment, the energy absorbing interlayer 30 has a Young's modulus that is at least 50 times smaller than the stiffness of the cover glass 18. In yet another embodiment, the energy absorbing interlayer 30 has a Young's modulus that is at least 100 times smaller than the stiffness of the cover glass 18.
The underlying device structure adjacent to the energy absorbing interlayer 30 may be a composite structure made of many different parts and materials. This is the case, for example, if the underlying device structure is a display module. In this case, determining the modulus of the underlying device structure may not be a simple matter. However, if the modulus of the energy absorbing interlayer 30 is several times smaller than the modulus of the cover glass 18, for example, 10 or more times smaller than the modulus of the cover glass 18, it may be assumed that the energy absorbing interlayer 30 will most likely be softer than the adjacent underlying device structure. Drop tests can be used to ascertain that an energy absorbing interlayer 30 having a particular Young's modulus will provide the desired impact energy absorption when used in a portable electronic device of a particular configuration.
There are ISTM standards for determining the elastic modulus of layered composites, such as D790 Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials; D3039/D3039M Test Method for Tensile Properties of Polymer Matrix Composite Materials; D3410/D3410M Test Method for Compressive Properties of Polymer Matrix Composite Materials with Unsupported Gage Section by Shear Loading; D3518/D3518M Test Method for In-Plane Shear Response of Polymer Matrix Composite Materials by Tensile Test of a 45 Laminate; D3552 Test Method for Tensile Properties of Fiber Reinforced Metal Matrix Composites; D5379/D5379M Test Method for Shear Properties of Composite Materials by the V-Notched Beam Method; E6 Terminology Relating to Methods of Mechanical Testing; E111 Test Method for Young's Modulus, Tangent Modulus, and Chord Modulus. Any appropriate one of these standards may be used to determine the modulus of the display module 26 and other composite underlying device structures if it is desired to verify that the energy absorbing interlayer 30 is softer than the adjacent underlying device structure.
The energy absorbing interlayer 30 can have a variety of geometries when viewed from its front surface 32 (or its back surface 34). In one example, the energy absorbing interlayer 30 may be in the form of a sheet extending across the back surface 19 of the cover glass 18.
The geometric definition of the energy absorbing interlayer 30 also includes the layer thickness (T in
Stiffness is a structural property influenced by the geometry of the structure and the materials used in the structure. The material and thickness of the energy absorbing interlayer 30 can be selected such that the energy absorbing interlayer 30 has a lower stiffness compared to the stiffness of the cover glass 18. The stiffness of a material is the extent to which the material can resist deformation in response to an applied force. The softer a material is, the less the material will be able to resist deformation in response to an applied force. Young's (or elastic) modulus provides a measure of the stiffness of an elastic material. In one embodiment, the material used in the energy absorbing interlayer 30 may have a Young's modulus selected from <20 GPa, <10 GPa, <1 GPa, <100 MPa, <1 MPa, and <0.1 MPa. In one embodiment, the layer thickness T of the energy absorbing interlayer 30 may be selected from >50 nm, >100 nm, >500 nm, >1 μm, >5 μm, >10 μm, >100 μm, >1 mm, and >5 mm. In general, the softer and thicker the energy absorbing interlayer 30, the better the reduction in contact force under drop. However, there are practical limits to the thickness of the energy absorbing interlayer 30 based on design specification of the device, such as user touch experience and overall thickness of the device. In one example, the energy absorbing interlayer 30 may have a Young's modulus in a range from 1 MPa to 100 MPa and a layer thickness in a range from 100 μm to 2.5 mm, where the the layer thickness could be uniform or non-uniform.
In one embodiment, the energy absorbing interlayer 30 is made of one or more polymers. The polymer(s) may be deposited as a film on the back surface 19 of the cover glass 18 using any suitable film deposition or coating process. Alternatively, the polymer may be provided as a separate element that can be disposed between the cover glass 18 and underlying device structure(s) of interest. Optically clear adhesive (OCA) is one example of a polymer product that can be used to form the energy absorbing interlayer 30. There are two types of OCA: liquid optically clear adhesive and optically clear adhesive made as a double-sided tape. One commercial example of liquid OCA is Printable Liquid Optically Clear Adhesive 1088 from 3M Company. The liquid OCA can be deposited on the back surface 19 of the cover glass 18 and then cured using, for example, UV radiation, to form the energy absorbing interlayer 30 on the back surface 19 of the cover glass 18. Commercial examples of OCA tapes are 3M Optically Clear Adhesive 821X and 9483AS from 3M Company. These OCAs are made of acrylic. The OCA tape can be applied to the back surface 19 of the cover glass 18. However, an additional process, such as autoclave, may be needed to remove any bubbles in the resulting energy absorbing layer 30. When used in the display area, the OCA will have the advantage of maintaining the optical performance of the display module 26. Other examples of materials that may be used in the energy absorbing interlayer 30 are foam materials and rubber or elastomer materials.
When the cover glass 18 hits a hard surface during a device drop event, the energy absorbing interlayer 30 will respond like a spring and dashpot system, dampening the impact of the contact force on the cover glass 18.
Solving for x in Equation (1) yields:
From Equation (2), softer springs (lower k) result in larger spring compression (larger x). This means that the electronic device 10 needs to travel a longer distance to come to a full stop before springing back. For the electronic device 10 with the same initial velocity, longer travel time means lower deceleration. According to Newton's second law (F=ma), lower a (acceleration) results in lower F (force). Here, F is the reaction force between the cover glass 18 and the hard surface. This provides a basis for the theory that using an energy absorbing interlayer 30 between the cover glass 18 and underlying device structure(s) will reduce the probability of cover glass damage due to sharp indentation.
A glass reliability performance study was conducted to demonstrate the above theory. Before the study was conducted, a decision had to be made about the criteria to use in comparing glass reliability performance. For this purpose, a static indentation study was conducted in which a sharp indenter was pushed against a glass surface.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
This application claims the benefit of priority under 35 U.S.C. §119 of U.S. Provisional Application Ser. No. 62/139,247 filed on Mar. 27, 2015, the content of which is relied upon and incorporated herein by reference in its entirety.
Number | Date | Country | |
---|---|---|---|
62139247 | Mar 2015 | US |