Composite Substrate for Flexible OLED Displays
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Solution Overview
Problem
Flexible displays using plastic substrates face issues with water vapor absorption, reducing their lifespan, while metal foil substrates lack external force distortion tolerance, necessitating a new method for fabrication that balances these constraints.
Innovation Solution
A method involving a composite layer with a polymer first layer, a metal layer, and a passivation layer, formed on a handling substrate, which includes a top-emitting organic light emitting unit and a reflective type liquid crystal display, where the metal layer prevents water vapor entry and enhances flexibility by peeling off from the substrate using a laser beam, forming a flexible and durable display.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If plastic substrates are used for flexible displays, then flexibility and external force distortion tolerance are improved, but water vapor barrier performance deteriorates
Solution Approach 1:
The patent applies composite materials by creating a multi-layer structure consisting of a plastic substrate layer and a metal foil layer bonded together. The plastic substrate provides flexibility and distortion tolerance, while the metal foil layer provides the water vapor barrier. This composite structure resolves the contradiction by combining materials with complementary properties rather than using a single material that must compromise between flexibility and barrier performance.
2Object-affected harmful factors
If metal foil substrates are used for flexible displays, then water vapor barrier performance is improved, but external force distortion tolerance deteriorates
Solution Approach 1:
The patent uses composite materials to combine metal foil and plastic substrate, where the metal foil provides the water vapor barrier and the plastic substrate provides the flexibility and distortion tolerance. This resolves the contradiction by allowing each material to contribute its superior property without being limited by its own weaknesses.
3Ease of manufacture
If conventional substrate materials are used, then manufacturing simplicity is maintained, but display lifespan deteriorates due to water vapor ingress
Solution Approach 1:
The patent applies composite materials by bonding a metal foil layer to a plastic substrate, creating a structure that simultaneously provides flexibility, water vapor barrier, and extended lifespan. The metal foil acts as an effective barrier against water vapor while the plastic substrate maintains flexibility, and both layers can be integrated using existing manufacturing processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution extends the operating lifespan of flexible displays by preventing water vapor ingress and improving external force resistance, addressing the limitations of both plastic and metal foil substrates, and can be applied to various flexible electronic devices.
Implementation Method 1
the water vapor barrier rate of plastic substrates is between 101 g/m2/day and 100 g/m2/day. On the other hand, the water vapor barrier rate of TFT-LCDs and OLEDs are respectively 10−4 g/m2/day and under 10−4 g/m2/day
Implementation Method 2
the metal layer prevents water vapor entry and enhances flexibility by peeling off from the substrate using a laser beam
Data Source
AI summary
A top-emitting OLED display and fabrication method thereof are provided. The top-emitting OLED display includes providing a handling substrate. A composite layer is formed on the handling substrate. An organic light emitting unit is formed on the composite layer. A top electrode is formed on the organic light emitting unit. A reflective type display and fabrication method thereof are provided. The reflective type display includes providing a handling substrate. A composite layer is formed on the handling substrate, a thin film transistor array is formed on the composite layer.