Display Panel Stress Relief via Segmented Substrate and Insulating Holes
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Solution Overview
Problem
Display panels experience cracking when moved along a curved surface due to high stress, particularly when rolled around a roller, leading to potential damage and reduced reliability.
Innovation Solution
A display panel design featuring a first display area, a second display area with a through portion, and a third display area, where the second display area includes an organic insulating layer with holes and an inorganic insulating layer extending between the first and third display areas, along with encapsulation layers and pattern layers to distribute stress and prevent cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the display panel is moved along a curved surface of a roller, then the display panel can be folded or rolled, but high stress causes cracking or damage to the display panel
Solution Approach 1:
The display panel is divided into multiple display areas (first, second, third display areas) with through portions that separate the substrate. This segmentation allows different regions to handle stress differently during rolling, with the through portions acting as stress relief points that prevent crack propagation while maintaining the overall structural integrity needed for foldability.
Solution Approach 2:
The organic insulating layer is selectively removed to form holes (first, second, and third display area holes) at specific locations between display elements and through portions. This local modification creates regions with different mechanical properties - the holes reduce stress concentration at critical points where cracks would otherwise initiate during rolling, while other areas maintain their original structure for structural support.
2Reliability
If the organic insulating layer is completely removed to reduce stress, then cracking is prevented, but display element functionality is compromised
Solution Approach 1:
The organic insulating layer is selectively removed only in specific regions to form holes, rather than being completely removed. The holes are positioned between display elements and through portions where stress concentration occurs during rolling. This localized removal reduces stress at critical points while preserving the organic insulating layer in other areas to maintain electrical insulation and structural integrity of display elements.
Solution Approach 2:
The holes in the organic insulating layer act as intermediary structures that mediate between the rigid substrate and the flexible display elements. These holes provide stress relief pathways that allow the display panel to deform during rolling without transmitting excessive stress to the display elements, while still maintaining sufficient structural support for element functionality.
3Reliability
If through portions are added to the substrate to reduce stress concentration, then cracking is prevented, but the substrate structure becomes more complex
Solution Approach 1:
The substrate is segmented by forming through portions that completely penetrate it, dividing the substrate into separate regions. These through portions create a segmented structure that allows independent movement and stress distribution in different areas during rolling, preventing stress concentration that would cause cracking. The segmentation is achieved through a standardized process that integrates with existing manufacturing workflows.
Solution Approach 2:
The formation of through portions is combined with the removal of the organic insulating layer to create holes, achieving multiple functions simultaneously. The through portions provide structural stress relief while the holes provide additional stress concentration reduction at the interface between display elements and substrate. This combined approach addresses both substrate-level and element-level stress issues in a single integrated structure.
Data Source
AI summary
A display panel comprising a first display area, a second display area including a through portion, and a third display area disposed between the first display area and the second display area. The display panel further comprises a substrate extending continuously from the first display area to the third display area and separating the substrate in the second display area. A plurality of display elements is arranged on the substrate and includes a first display element, a second display element, and a plurality of third display elements. An organic insulating layer is arranged between the substrate and the plurality of display elements and includes a second display area hole disposed between the second display element and the through portion, and a third display area hole disposed between adjacent third display elements of the plurality of third display elements.