Display Device Support Layer Side Wall Adhesion Overflow

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Solution Overview

Problem

Thin display devices face challenges with stiffness when using substrates of thinner thickness, leading to issues with the adhesion layer overflowing and causing difficulties in separating the carrier from the support layer during the manufacturing process.

Innovation Solution

A display device design featuring a support layer with specific side walls and angles greater than 0 degrees and less than 180 degrees, along with an adhesion layer and a flexible base layer, prevents the adhesion layer from overflowing and adhering to the carrier, ensuring easy separation by creating a non-uniform surface for the adhesion layer to flow and adhere on.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If a substrate with thinner thickness is used to reduce the weight and thickness of the display device, then the weight and thickness are reduced, but the stiffness of the substrate becomes insufficient

Engineering Contradiction:

Improveweight of display deviceVSAvoidstiffness of substrate

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent uses a composite structure consisting of a flexible substrate combined with a support layer having a specific side wall configuration. This composite approach allows the thin flexible substrate to maintain structural integrity and stiffness while keeping the overall device thin and light. The support layer with its angled side walls provides mechanical reinforcement without adding significant thickness or weight.

Inventive Principle:

Principle #40Composite materials

2Strength

If the adhesion layer is applied on a support layer with uniform surface, then the adhesion is strong, but the adhesion layer overflows and adheres to the carrier making separation difficult

Engineering Contradiction:

Improveadhesion strengthVSAvoidease of carrier separation

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent introduces asymmetry in the support layer design by creating a side wall with a specific angle (α) relative to the top surface. This asymmetric geometry prevents the adhesion layer from flowing uniformly in all directions, controlling its overflow behavior and preventing adhesion to the carrier while maintaining strong adhesion where needed.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The support layer is designed with different surface properties in different regions: the top surface provides a uniform plane for strong adhesion, while the angled side wall creates a non-uniform surface that controls adhesion layer flow and prevents carrier adhesion. This local differentiation of surface quality solves both adhesion and separation requirements.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10647085B2Display device and electronic device

Publication Date: 2020.05.12 INNOLUX CORP

AI summary

A display device is disclosed, which includes: a support layer including a first surface, a second surface and a first side wall, wherein the first surface and the second surface locate at two opposite sides of the support layer, and the first side wall connects the first surface and the second surface; an adhesion layer disposed on the second surface of the support layer; a base layer disposed on the adhesion layer; and at least one transistor disposed on the base layer, wherein the adhesion layer adheres to a partial portion of the first side wall of the support layer.