Flexible Array Substrate Structure for Bending Stress Dispersion
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Solution Overview
Problem
Conventional array substrates for flexible display panels face challenges in dispersing bending stress and have complex, costly manufacturing processes, making them inefficient and expensive.
Innovation Solution
The array substrate design includes a substrate layer with a metal layer comprising light-shading blocks arranged at intervals, which improves surface roughness and adhesion, and a second substrate layer forming bumps to disperse bending stress, replacing the need for a light-shading layer and buffer holes, thereby simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional array substrate design is used for flexible display panels, then the basic structural requirements are met, but the bending stress cannot be effectively dispersed and the manufacturing process is complex and costly
Solution Approach 1:
The substrate layer is segmented into multiple functional layers including first and second substrate layers, first and second barrier layers, and a metal layer with light-shading blocks. This segmentation allows each layer to perform specific functions: the barrier layers prevent water and oxygen penetration, the metal layer provides light shielding and structural support, and the substrate layers provide mechanical flexibility. The segmented design enables effective stress dispersion during bending while simplifying the manufacturing process by assigning specific functions to each layer.
Solution Approach 2:
The metal layer serves multiple functions simultaneously: it acts as a light-shading layer to block light from reaching the TFT structures, provides structural support to enhance bending resistance, and forms light-shading blocks that can be patterned to define pixel regions. The first and second barrier layers collectively provide protection against water and oxygen penetration. This multi-functionality reduces the need for separate dedicated layers, thereby simplifying the overall manufacturing process while maintaining reliability.
2Reliability
If a light-shading layer and buffer holes are included in the array substrate, then light shielding and structural support are provided, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The patent merges the light-shading function and structural support function into a single metal layer. The metal layer is patterned to form light-shading blocks that provide both light shielding and structural reinforcement. This eliminates the need for a separate light-shading layer and reduces the number of manufacturing steps. Additionally, the barrier layers are designed to work together as an integrated protection system, further simplifying the manufacturing process while maintaining the necessary light shielding and structural support.
Solution Approach 2:
The patent extracts the light-shading function from a dedicated light-shading layer and integrates it into the metal layer structure. By forming light-shading blocks within the metal layer through patterning, the design eliminates the need for a separate light-shading layer and its associated manufacturing steps. This extraction and integration approach simplifies the manufacturing process while maintaining effective light shielding and structural support.
Data Source
AI summary
The embodiment of the present invention discloses an array substrate and a manufacturing method thereof. The array substrate includes a substrate layer, and a thin-film transistor structure layer disposed on the substrate layer. The substrate layer includes a first substrate layer; a first barrier layer disposed on the first substrate layer; a metal layer disposed on the first barrier layer, and the metal layer includes a plurality of light-shading blocks arranged at intervals; and a second substrate layer disposed on the metal layer and covering the plurality of light-shading blocks arranged at intervals.