Fabric substrate and manufacturing method thereof
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Solution Overview
Problem
Wearable displays using fabric substrates face challenges with surface roughness, instability of light emitting elements, material deformation, and limited flexibility due to heat application, making them difficult to achieve foldability or stretchability.
Innovation Solution
A fabric substrate is developed with a stress buffer layer and a flattening layer, where the stress buffer layer is formed of a material with elasticity and adhesiveness, and the flattening layer has low surface roughness, allowing for a smooth surface for light emitting elements. The manufacturing process involves a sacrificial layer and UV curing to ensure flexibility and adhesion without heat application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If polymers are bound to the entire surface of the fabric and the fabric is flattened, then the wearable display becomes flexible, but large physical strain and stress occur making foldability and stretchability difficult to achieve
Solution Approach 1:
The fabric substrate is divided into three distinct layers: fabric layer, stress buffer layer, and flattening layer. This segmentation allows each layer to perform its specific function - the stress buffer layer absorbs strain while the flattening layer provides a smooth surface, resolving the contradiction between flexibility and stress resistance
Solution Approach 2:
The stress buffer layer acts as an intermediary between the fabric layer and the flattening layer. It absorbs and buffers the physical strain and stress generated by fabric deformation, preventing this stress from being transmitted to the light emitting elements while still allowing the overall structure to remain flexible
2Reliability
If thermocompression bonding is used to bond a plastic substrate to the fabric, then the light emitting element can operate on the fabric, but the plastic substrate and fabric are deformed by heat limiting material selection
Solution Approach 1:
The patent replaces thermal bonding (thermocompression) with UV-curable adhesive bonding. The UV curable adhesive is applied to the fabric layer and cured using UV irradiation instead of heat, eliminating thermal deformation of materials while maintaining strong bonding between layers
Solution Approach 2:
The bonding method changes from thermal parameters (heat and pressure) to photopolymerization parameters (UV irradiation intensity and exposure time). This parameter change allows heat-sensitive materials like fabric and plastic substrates to be bonded without deformation, expanding material selection flexibility
3Reliability
If solution coating is used to coat the fabric, then the light emitting element can be operated on the fabric, but the rough surface of the fabric cannot be sufficiently smoothed affecting stable operation
Solution Approach 1:
The substrate structure is segmented into multiple functional layers, with the flattening layer specifically dedicated to providing a smooth surface. This segmentation allows the fabric layer to maintain its flexible, breathable properties while the flattening layer provides the required surface precision for stable light emitting element operation
Solution Approach 2:
The patent uses a composite structure combining fabric layer, stress buffer layer, and flattening layer. The flattening layer, made of materials with low surface roughness, is composite-bonded to the fabric through UV-curable adhesive, achieving both flexibility and surface smoothness simultaneously
4Strength
If heat is applied to the fabric during manufacturing, then bonding can be achieved, but strain occurs reducing flexibility and breathability
Solution Approach 1:
Thermal bonding is replaced with UV-curable adhesive bonding. The UV curable adhesive forms strong chemical bonds between layers through photopolymerization when exposed to UV light, achieving bonding strength without applying heat that would cause fabric strain and reduce flexibility
Solution Approach 2:
The bonding process utilizes the phase transition of UV curable adhesive from liquid to solid through photopolymerization. This phase change occurs at room temperature under UV irradiation, providing strong bonding without thermal effects that would damage fabric flexibility and breathability
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 fabric substrate achieves low surface roughness, excellent interface properties, and maintains flexibility without strain, enabling stable operation of light emitting elements and allowing for repetitive bending, while maintaining breathability and elasticity.
Implementation Method 1
a UV curable adhesive is applied between the fabric layer and the plastic substrate, and UV rays are irradiated to the UV curable adhesive to bind the fabric layer and the plastic substrate to each other
Data Source
AI summary
According to the present invention, there is provided a fabric substrate for mounting a light emitting element. The fabric substrate comprises a fabric layer including at least one fabric, a stress buffer layer that is disposed on the fabric layer and minimizes an occurrence of physical strain and stress caused by bending the fabric layer, and a flattening layer that is disposed on the stress buffer layer and provides a flat surface to allow a light emitting element to operate.