Manufacturing method of foldable screen and foldable screen

Abstract

This invention provides a method for manufacturing a foldable screen and a foldable screen in general. The manufacturing method includes four steps: preparing a self-healing substrate, depositing an OLED component on the substrate, applying a self-healing capping layer to the surface of the OLED component, and constructing a precision pressure distribution control system to achieve uniform pressure distribution during the folding process. By using a substrate and capping layer with self-healing properties, as well as a precision pressure distribution control system, the durability and reliability of the foldable screen are significantly improved.

Description

Technical Field

[0001] This invention relates to the field of screen manufacturing technology, and in particular to a method for manufacturing a foldable screen and a foldable screen. Background Technology

[0002] Foldable screen technology is a major innovation in the field of mobile devices in recent years. It allows the screen to be folded or bent while maintaining its display function. The development of this technology aims to combine the visual experience of a large screen with the portability of a small device, providing users with more flexible and diverse ways to use the device.

[0003] Existing foldable screen technology faces durability challenges. Frequent folding operations may cause screen damage, such as screen creases, substrate fatigue, or cover layer cracking. In addition, foldable screens have poor stability and reliability under different environmental conditions (such as changes in temperature and humidity).

[0004] Therefore, it is necessary to design a manufacturing method for foldable screens and a foldable screen to solve the above problems. Summary of the Invention

[0005] This invention provides a method for manufacturing a foldable screen and a foldable screen in general, which addresses the technical problems mentioned in the background art.

[0006] To address the above problems, the present invention provides the following technical solution: a method for manufacturing a foldable screen, comprising the following steps: S1 is used to prepare a substrate with self-healing properties; S2 deposits OLED components on the substrate; S3 applies a self-healing coating to the surface of the OLED component; S4 features a precision pressure distribution control system to achieve uniform pressure distribution during the folding process.

[0007] Furthermore, the substrate is prepared by a chemical synthesis process of shape memory polymer and crosslinked modified polyurethane, which includes mixing a crosslinking agent and a catalyst with the shape memory polymer and crosslinked modified polyurethane at room temperature and carrying out a crosslinking reaction for at least 24 hours; wherein the weight ratio of the shape memory polymer to the crosslinked modified polyurethane is 1:1, the amount of crosslinking agent added is 10% of the total weight of the mixture of shape memory polymer and crosslinked modified polyurethane, and the amount of catalyst added is 2% of the total weight of the mixture of shape memory polymer and crosslinked modified polyurethane.

[0008] Furthermore, the weight ratio of the shape memory polymer to the crosslinked modified polyurethane is 1:1.

[0009] Furthermore, the deposition of the OLED components is achieved using ultra-precision inkjet printing.

[0010] Furthermore, the inkjet printing technology uses a printer with a 10-nanometer aperture printhead to achieve a pixel density of at least 2048 PPI.

[0011] Furthermore, the self-healing coating comprises silica nanoparticle-reinforced silicone.

[0012] Furthermore, the amount of silica nanoparticles added is 5% of the total weight of the capping layer.

[0013] Furthermore, the silicone is exposed to ultraviolet light with an intensity of 100 mW / cm² for two minutes to form a cover layer with a thickness of 0.05 mm.

[0014] Furthermore, the precision pressure distribution control system includes micro motors, each connected to an elastic support point, and the extension and retraction of each support point are adjusted in real time by a microcontroller unit (MCU) based on data fed back from the pressure sensing layer.

[0015] The present invention also provides a foldable screen for use in electronic products, wherein the foldable screen is manufactured by any of the manufacturing methods described above.

[0016] Compared with the prior art, the present invention has at least the following beneficial effects: This invention significantly improves the durability and reliability of foldable screens by using a substrate and cover layer with self-healing properties. The self-healing material automatically repairs minor scratches and damage, extending the lifespan of the foldable screen and maintaining its appearance and performance. Furthermore, the precision pressure distribution control system achieves uniform pressure distribution during folding, reducing screen damage or performance degradation caused by uneven pressure, and ensuring the stability and reliability of the foldable screen during repeated folding and use. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Figure 1 This is a flowchart of the foldable screen manufacturing method in an embodiment of the present invention. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present invention. It is understood that the accompanying drawings are provided for reference and illustration only, and are not intended to limit the present invention. The connection relationships shown in the accompanying drawings are only for clear description and do not limit the connection method.

[0019] This invention discloses a method for manufacturing a foldable screen, which aims to improve the durability and reliability of foldable screens.

[0020] For details, please refer to Figure 1 The manufacturing method includes the following steps: Step S1: Prepare a substrate with self-healing properties; Material preparation: First, prepare shape memory polymer and crosslinked modified polyurethane, ensuring that the purity of both is suitable for the chemical synthesis process; in this embodiment, the shape memory polymer is selected as polyurethane-based shape memory polymer, and the crosslinked modified polyurethane is selected as polyurethane modified by adding a small amount of crosslinking agent.

[0021] Synthesis process: The shape memory polymer and crosslinked modified polyurethane are mixed at a weight ratio of 1:1. 10% by weight of a crosslinking agent (an isocyanate compound in this example) and 2% by weight of a catalyst (dimethyltin in this example) are added to the mixture. The mixture is stirred at room temperature for at least 30 minutes to ensure thorough mixing. The mixture is then poured into a pre-prepared mold and left at room temperature for at least 24 hours to complete the crosslinking reaction and form a substrate with self-healing properties.

[0022] In this embodiment, isocyanate compounds are used as crosslinking agents. Isocyanate compounds have high reactivity and can react with the hydroxyl groups of the polymer at room temperature to form strong urea or urea bonds. This eliminates the need for additional heating during the preparation process, simplifying the manufacturing process.

[0023] In this embodiment, dimethyltin is used as a catalyst, and it exhibits good catalytic activity even at extremely low concentrations. This helps to control costs while reducing potential environmental impact.

[0024] By using a substrate and cover layer with self-healing properties, this technology significantly improves the durability and reliability of foldable screens. The self-healing material can automatically repair minor scratches and damage, extending the lifespan of the foldable screen and maintaining its appearance and performance.

[0025] Step S2: Deposit OLED components on the substrate; Solvent and OLED material formulation: Prepare a suitable OLED material solution for inkjet printing, including a suitable organic solvent and OLED precursor. Solvent selection is based on its boiling point and surface tension to suit the inkjet printing process; Inkjet printing: Using an inkjet printer equipped with a printhead with an aperture of at least 10 nanometers, print parameters were adjusted to achieve a pixel density of at least 2048 PPI. During printing, the substrate temperature was maintained within a suitable range to optimize the deposition and curing of the OLED material.

[0026] In preparing OLED material solutions, the key lies in selecting appropriate luminescent materials (host materials and guest materials) and solvents; in this embodiment, for a specific formulation: Host material: Materials with good electron and hole transport properties, such as 4,4'-N,N'-dicarbazole-biphenyl (CBP), are usually selected as blue light host materials.

[0027] Guest material (dopant): Select organophosphorus or iridium complexes with high luminescence efficiency and good spectral characteristics, such as Ir(ppy)3 (triphenyliridium) as green light emitting material.

[0028] Solvent: A solvent with good solubility for OLED materials and good inkjet printing properties should be selected, such as toluene, chlorobenzene, or a mixed solvent system, to meet the needs of inkjet printing.

[0029] For OLED emissive layer solution formulations, the solvent-to-emissive material ratio may need to be determined experimentally, depending on solubility and desired solution viscosity. A starting point is a total concentration of host and guest materials between 0.5% and 2% (weight / volume), with the guest material doping concentration being approximately 1% to 8% (relative to the weight of the host material).

[0030] In determining the doping concentration of the guest material relative to the host material, the applicant conducted experiments for comparison. Five OLED material solutions were prepared, with the following weight ratios of CBP and Ir(ppy)3 in each solution: A: 100:0 (Control group, without Ir(ppy)3) B: 98:2 C: 95:5 D: 90:10 E: 85:15 The total solute concentration in each solution group was maintained at 1% (w / v), using toluene as the solvent. OLED material was deposited on the pretreated substrate using the same inkjet printing technology and cured under the same UV conditions.

[0031] Experimental results: Luminous efficiency: Measuring the luminous efficiency (cd / A) of each sample group under standard test conditions revealed that the luminous efficiency first increased and then decreased with the increase of the Ir(ppy)3 ratio. Group C (95:5 ratio) showed the highest luminous efficiency, indicating that appropriate doping of guest materials can significantly improve the luminous efficiency of OLEDs.

[0032] Color purity: The emission spectrum of each sample was measured by a spectrometer. It was found that group C (95:5 ratio) showed the best color purity with a narrower spectral half-width, indicating that the doping ratio has a significant impact on the adjustment of OLED color purity.

[0033] in conclusion: Experimental data shows that the optimal ratio of CBP to Ir(ppy)3 is 95:5. This ratio not only provides the highest luminous efficiency but also ensures good color purity. This discovery is crucial for optimizing the performance of OLED components. By adjusting the ratio of host to guest materials, the photoelectric properties of OLEDs can be effectively controlled to meet the efficiency and display quality requirements of different applications.

[0034] In this embodiment, ultra-precision inkjet printing technology is used to deposit OLED components, achieving a high pixel density (at least 2048 PPI), which can provide a clearer and more delicate display effect. This high-resolution printing technology ensures color accuracy and uniformity, improving the visual experience.

[0035] Step S3: Apply a self-healing capping layer to the surface of the OLED component; Coating preparation: Silica nanoparticles were uniformly dispersed in the silica prepolymer at a ratio of 5±1%. The mixture was cured under ultraviolet light irradiation (intensity above 100 mW / cm²) for 2 minutes to form a self-healing coating with a thickness of 0.05±0.01 mm, thereby enhancing scratch resistance and self-healing speed.

[0036] S4 constructs a precision pressure distribution control system to achieve uniform pressure distribution during the folding process; System configuration: Micromotors and flexible support points are arranged below the foldable screen. Specifically, one to two micromotors and corresponding flexible support points are arranged per square inch of screen, and each support point is precisely controlled by a micromotor. The layout and number of micromotors are optimized according to the screen size and the expected folding area.

[0037] Control strategy: Using data collected by the microcontroller unit (MCU) and pressure sensing layer, the support points driven by each micro motor are adjusted in real time to ensure uniform pressure distribution during folding.

[0038] During the severe folding screen durability test, a mechanical device was used to simulate the opening and closing operation of the folding screen, with the folding frequency set at 20 times per minute; the test folding cycle was set to 100,000 times to simulate long-term use; after completing 100,000 folding cycles, the display quality of the folding screen (including brightness and color saturation) showed only slight changes compared to the initial state, with no obvious performance degradation; no obvious fatigue damage or structural breakage was observed in the folding area.

[0039] The precision pressure distribution control system enables uniform pressure distribution during folding, reducing screen damage or performance degradation caused by uneven pressure. This system ensures the stability and reliability of the foldable screen during repeated folding and use.

[0040] In addition, the present invention also discloses a foldable screen, which is manufactured using the above-described manufacturing method.

[0041] The foldable screen manufactured by the method of the present invention comprehensively improves the durability, display effect, reliability and user experience of the foldable screen.

[0042] In the specification and claims of this application, the terms "comprising / including" and "having / including" and variations thereof are used to specify the presence of the stated features, values, steps or components, but do not exclude the presence or addition of one or more other features, values, steps, components or combinations thereof.

[0043] Some features of the present invention are described in different embodiments for clarity; however, these features may also be described in combination in a single embodiment. Conversely, some features of the present invention are described only in a single embodiment for brevity; however, these features may also be described individually or in any suitable combination in different embodiments.

[0044] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for manufacturing a foldable screen, characterized in that, Includes the following steps: S1 prepares a substrate with self-healing properties; the substrate is formed by mixing shape memory polymer and cross-linked modified polyurethane in a weight ratio of 1:1, adding 10% of the total weight of cross-linking agent and 2% of the total weight of catalyst to the mixture, and carrying out a cross-linking reaction at room temperature for at least 24 hours; S2 deposits OLED components on the substrate; S3 applies a self-healing capping layer to the surface of the OLED component; the self-healing capping layer comprises silica nanoparticle-reinforced silicone, the amount of silica nanoparticles added being 5±1% of the total weight of the capping layer; S4 constructs a precision pressure distribution control system to achieve uniform pressure distribution during the folding process; the precision pressure distribution control system includes micro motors, each micro motor is connected to an elastic support point, and the extension and contraction of each support point are adjusted in real time based on the data fed back from the pressure sensing layer by a microcontroller unit (MCU).

2. The method for manufacturing a foldable screen according to claim 1, characterized in that, The OLED components are deposited using ultra-precision inkjet printing.

3. The method for manufacturing a foldable screen according to claim 2, characterized in that, The inkjet printing uses a printer with a printhead having an aperture of at least 10 nanometers to achieve a pixel density of at least 2048 PPI.

4. The method for manufacturing a foldable screen according to claim 1, characterized in that, The silicone has a strength of 100mW / cm. 2 The above process involves exposure and curing under ultraviolet light to form a coating layer with a thickness of 0.05 ± 0.01 mm.

5. A foldable screen, used in electronic products, characterized in that, The foldable screen is manufactured by the manufacturing method described in any one of claims 1 to 4.

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