Flexible Display Opening via Protrusion Pattern Separation

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Solution Overview

Problem

Existing display device manufacturing methods are inefficient in creating openings for inserting modules like cameras, often requiring costly processes and risking impurity introduction, especially when trying to increase the display area relative to the non-display area.

Innovation Solution

A manufacturing method involving the formation of a protrusion pattern on a carrier glass, followed by coating a polymer layer, and then separating the carrier glass and pattern from the polymer layer to create an opening that penetrates the stacked structure, including a transistor and organic light emitting element, allowing for a flexible display device with enhanced module insertion capabilities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional methods are used to create openings for module insertion, then the opening can be formed, but the process is complex, costly, and risks introducing impurities

Engineering Contradiction:

Improveopening creation processVSAvoidimpurity introduction risk

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The protrusion pattern is formed on the carrier glass before the polymer layer is coated. This preliminary structuring allows the opening to be automatically formed during the separation process without requiring additional opening-creation steps, thereby simplifying the manufacturing process and reducing impurity risks

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protrusion pattern acts as an intermediary structure between the carrier glass and the polymer layer. During separation, this intermediary structure enables the opening to be formed cleanly as the protrusion pattern is removed from the polymer layer, avoiding direct mechanical or chemical etching that could introduce impurities

Inventive Principle:

Principle #24Intermediary (Mediator)

2Area of stationary object

If the display area is increased relative to the non-display area, then the display device becomes more efficient, but creating openings for modules becomes more difficult

Engineering Contradiction:

Improvedisplay areaVSAvoidopening creation difficulty

Core Design Contradiction:

Area of stationary objectVSEase of manufacture

Solution Approach 1:

The carrier glass is segmented into a protrusion pattern that corresponds to the desired opening location. This segmentation allows the opening to be precisely positioned in the display area without requiring post-processing steps, enabling increased display area while maintaining ease of module insertion

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The protrusion pattern is prepared in advance on the carrier glass at the exact location where the opening is needed. This preliminary positioning ensures that even in high-display-area designs where opening locations are critical, the opening can be easily created during separation without complicating the overall manufacturing process

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If complex processes are used to create openings, then openings can be formed, but the manufacturing cost and process load increase

Engineering Contradiction:

Improveopening formationVSAvoidprocess load

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The opening formation process is merged with the carrier glass separation process. The protrusion pattern is formed during the initial carrier glass preparation, and the opening is automatically created when the carrier glass is separated from the polymer layer, eliminating the need for separate opening-creation processes and reducing overall process load

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

All necessary structuring for the opening is performed preliminarily on the carrier glass before polymer coating. This ensures that the opening can be formed with high precision during separation without requiring additional complex processing steps, thereby maintaining manufacturing precision while reducing process load

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10431762B2Display device and manufacturing method thereof

Publication Date: 2019.10.01 SAMSUNG DISPLAY CO LTD

AI summary

A manufacturing method of a display device according to some embodiments includes: forming a protrusion pattern on a carrier glass; coating a polymer on the protrusion pattern to form a polymer layer; forming a stacked structure on the polymer layer, including a transistor and an organic light emitting element connected to the transistor; and separating the carrier glass and the protrusion pattern from the polymer layer, wherein an opening penetrating the polymer layer is formed during the separation of the protrusion pattern.