Drive Substrate Protective Layer Layout for Bonding Reliability
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Solution Overview
Problem
In the manufacturing of Micro/Mini LED display products, the adhesive force between the flexible substrate and the supporting substrate is reduced due to laser cutting, leading to swelling and disengagement issues in high-temperature high-humidity environments, which affects the reliability and yield of the display products.
Innovation Solution
A driving base plate design with a functional region and a peripheral region, where the flexible substrate is protected by a series of layers including a protecting layer, buffer layers, and passivation layers, which cover the surface and sides of the flexible substrate to prevent water vapor contact and enhance adhesive force, and a method for manufacturing this base plate involving the formation and patterning of these layers on a rigid mother-board substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If laser cutting is used to separate driving base plates, then large-area display products can be manufactured through splicing, but the adhesive force between the flexible substrate and the supporting substrate is reduced
Solution Approach 1:
The patent applies different structural configurations to different regions of the driving base plate. The flexible substrate is positioned within the functional region with specific overlapping relationships to the supporting substrate, while the peripheral region provides additional structural support. This local differentiation maintains adhesive force in critical areas while enabling laser cutting for large-area splicing applications.
2Adaptability or versatility
If the flexible substrate is exposed in high-temperature high-humidity environment, then the device can operate, but the flexible substrate absorbs water and becomes disengaged
Solution Approach 1:
The patent employs the flexible substrate as a contained element within a structured assembly. The flexible substrate is positioned and constrained within the driving base plate structure, allowing it to flexibly adapt to environmental conditions while maintaining its bonded relationship with the supporting substrate through the designed overlapping configuration.
Solution Approach 2:
The driving base plate utilizes a composite structure combining the flexible substrate with the supporting substrate in a specific spatial arrangement. This composite configuration creates a synergistic structure where the flexible substrate provides operational adaptability while the supporting substrate and their overlapping region maintain bonding reliability under high-temperature high-humidity conditions.
3Quantity of substance
If the flexible substrate overlaps extends beyond the supporting substrate, then the flexible substrate can be fully utilized, but the adhesive force is further reduced and disengagement occurs
Solution Approach 1:
The patent optimizes the spatial relationship between the flexible substrate and supporting substrate by confining the flexible substrate within the functional region boundaries. This localized positioning ensures that the flexible substrate is fully utilized for its intended function while maintaining optimal adhesive contact with the supporting substrate, preventing disengagement.
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 effectively increases the adhesive force between the flexible substrate and the supporting substrate, preventing swelling and disengagement, thereby improving the reliability and yield of the display products and enabling the production of large-area display products through splicing.
Implementation Method 1
the flexible substrate further absorbs water and thus is disengaged
Data Source
AI summary
A driving base plate includes a functional region (A) and a peripheral region (B) surrounding the functional region (A). Both the functional region (A) and the peripheral region (B) include a supporting substrate, and the functional region (A) further includes a flexible substrate and at least one protecting layer that are sequentially arranged on the supporting substrate. The region of the orthographic projection of the flexible substrate on the supporting substrate is located within the region where the supporting substrate within the functional region (A) is located, and the protecting layer covers the surface of the flexible substrate further from the supporting substrate and the side of the flexible substrate close to the peripheral region (B). The adhesive force between the flexible substrate and the supporting substrate of the driving base plate is increased, and the reliability of the products manufactured by using the driving base plate is improved.