Bendable Display Panel Manufacturing With Temporary Protective Films
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Solution Overview
Problem
Existing methods for manufacturing bendable display apparatuses result in high defect rates and increased manufacturing costs due to issues with durability and lifespan.
Innovation Solution
A method involving the use of a flexible mother substrate with a carrier substrate, temporary protective film, and controlled adhesive forces, along with strategic openings and layers to manage stress during bending, reduces defects and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a bendable display apparatus is manufactured using conventional methods, then the display can be bent to improve visibility and reduce non-display area, but defects occur and lifespan is reduced
Solution Approach 1:
The patent divides the substrate into multiple regions with different properties: a first substrate region that remains flat and a second substrate region that is bent. This segmentation allows different parts of the display apparatus to have different mechanical characteristics, enabling bending capability in specific areas while maintaining structural integrity and reducing defects in other areas.
Solution Approach 2:
The patent applies local quality by creating a bent region with specific mechanical properties in the second substrate region, while the first substrate region maintains its original flat structure. This localized bending approach allows the display to achieve adaptability in specific areas without compromising the overall reliability and lifespan of the entire apparatus.
2Area of stationary object
If the display is bent to reduce non-display area, then visibility is improved, but stress on conductive layers increases causing defects
Solution Approach 1:
The patent segments the substrate into flat and bent regions, confining the bending-induced stress to the second substrate region. This segmentation prevents stress from propagating to the conductive layers in the first substrate region, thereby maintaining their integrity while still achieving the goal of reducing non-display area through bending.
Solution Approach 2:
The patent creates local quality differences by bending only the second substrate region while keeping the first substrate region flat. This localized bending reduces the overall stress on conductive layers by concentrating deformation in a controlled area, thus improving visibility without causing widespread defects.
3Ease of manufacture
If manufacturing methods are simplified to reduce costs, then manufacturing efficiency increases, but defect rate increases
Solution Approach 1:
The patent employs segmentation to create distinct flat and bent substrate regions, which can be manufactured using standardized processes. This approach simplifies manufacturing by avoiding the need for complex custom shaping while maintaining high reliability through controlled stress distribution that prevents defects in the conductive layers.
Data Source
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AI summary
A method of manufacturing a display apparatus, which is capable of reducing manufacturing costs and a defect rate during manufacturing, and a display apparatus. The method includes forming a plurality of display units over a mother substrate; attaching a temporary protective film to a lower surface of the mother substrate; cutting the mother substrate and the temporary protective film along a periphery of each of the plurality of display units to obtain a plurality of display panels each including a first area, a second area, and a bent area between the first area and the second area; removing the temporary protective film from the plurality of display panels; and attaching a lower protective film to a lower surface of each of the plurality of display panels so as to correspond to the first area in each display panel.