Flexible AMOLED Substrate Bending Section Buffer Layer Reduction

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Solution Overview

Problem

Flexible AMOLED substrates with thick inorganic insulation layers in the bending section exhibit poor resistance to bending, leading to breakage and reduced production yield.

Innovation Solution

A manufacturing method that involves forming a flexible backing with a display section and a bending section, where a portion of the buffer layer on the bending section is removed while preserving it on the display section, using a half-mask based process to reduce the thickness of the inorganic insulation layer in the bending section, thereby enhancing bending resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the buffer layer is provided on the bending section to ensure complete insulation coverage, then the insulation reliability is improved, but the bending resistance deteriorates due to increased thickness

Engineering Contradiction:
Improveinsulation reliabilityVSAvoidbending resistance
Core Design Contradiction:
ReliabilityVSStrength

Solution Approach 1:

The patent applies local quality by providing the buffer layer only in specific regions: on the display section and on the bending section only at positions not overlapping with the gate insulation layer. This selective placement ensures that the buffer layer provides necessary insulation where needed while avoiding areas where it would compromise bending flexibility, thus resolving the contradiction between insulation reliability and bending resistance.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent segments the buffer layer into distinct regions: a first buffer layer portion on the display section and a second buffer layer portion on the bending section. The second portion is specifically positioned to overlap with the flexible backing but not with the gate insulation layer. This segmentation allows different parts of the buffer layer to serve different functions, maintaining insulation where required while preserving bending capability in critical areas.

Inventive Principle:
Principle #1Segmentation

2Strength

If the buffer layer is removed from the bending section to improve bending resistance, then the bending resistance is improved, but the insulation coverage deteriorates

Engineering Contradiction:
Improvebending resistanceVSAvoidinsulation coverage
Core Design Contradiction:
StrengthVSReliability

Solution Approach 1:

The patent ensures that the buffer layer is strategically positioned to provide insulation only where necessary. On the bending section, the buffer layer is applied only in areas that do not overlap with the gate insulation layer, creating a local insulation solution that maintains electrical isolation where needed while leaving other areas open for bending flexibility.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The buffer layer is divided into functional segments: the first portion on the display section provides comprehensive insulation, while the second portion on the bending section provides targeted insulation only where it does not interfere with bending. This segmentation resolves the contradiction by distributing insulation coverage selectively across different regions.

Inventive Principle:
Principle #1Segmentation

3Manufacturing precision

If the gate insulation layer and buffer layer are formed in separate processes, then the manufacturing precision is improved, but the device complexity increases

Engineering Contradiction:
Improvelayer alignment precisionVSAvoidfabrication process complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges the formation of the gate insulation layer and the buffer layer into a single coating process. The gate insulation layer and buffer layer are deposited simultaneously in one step, eliminating the need for separate formation processes and reducing overall fabrication complexity while maintaining proper layer alignment and insulation functionality.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The single coating process serves multiple functions: it forms both the gate insulation layer and the buffer layer in one operation. This multi-functional approach simplifies the manufacturing process by consolidating what would otherwise require separate steps, reducing device complexity while maintaining manufacturing precision through controlled deposition parameters.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Data Source

PatentUS10790458B2Flexible AMOLED substrate and manufacturing method thereof
Publication Date: 2020.09.29 WUHAN CHINA STAR OPTOELECTRONICS SEMICONDUCTOR DISPLAY TECHNOLOGY CO LTD
  • US10790458B2 patent drawing
  • US10790458B2 patent drawing
  • US10790458B2 patent drawing

AI summary

A flexible AMOLED substrate and a manufacturing method thereof are provided. The method includes: forming a flexible backing, which includes a display section and a bending section disposed on an outer circumference of the display section; forming a buffer layer on the flexible backing, removing a portion of the buffer layer that is disposed on the bending section and preserving a portion of the buffer layer that is disposed on the display section so that an inorganic insulation layer on the bending section has a reduced thickness to improve bending resistance of the bending section of the flexible AMOLED substrate and thus improving production yield. The flexible AMOLED substrate is manufactured with the above method, in which an inorganic insulation layer included in a bending section has a reduced thickness so that the bending section of the flexible AMOLED substrate shows better resistance against bending and provides high production yield.