Flexible Display Panel Anisotropic Conductive Film Reliability
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Solution Overview
Problem
Conventional flexible display panels using plastic substrates face issues with poor electrical contact and reduced reliability due to the breakage of metal lines and immersion of conductive particles when employing anisotropic conductive films, as the existing technologies like COG and FOG result in inadequate hot-pressing pressure and temperature settings.
Innovation Solution
The use of anisotropic conductive films with conductive particles of diameters ranging from 4.5 to 7 micrometers and a distribution density of 45,000 to 65,000 grains per square millimeter, which improves electrical connectivity and prevents particle immersion, allowing for higher reliability by adjusting the hot-pressing pressure to 0.5-1 MPa and temperature to 150-210°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional anisotropic conductive film with particle diameter of 3-4 micrometers and density of 32000 grains per square millimeter is used, then the joining process can be performed, but metal lines break and conductive particles immerse into the plastic substrate, reducing reliability
Solution Approach 1:
The patent changes the parameters of the anisotropic conductive film by increasing particle diameter from 3-4 micrometers to 5-10 micrometers and adjusting distribution density from 32000 to 40000-70000 grains per square millimeter. This parameter change prevents particle immersion into the plastic substrate while maintaining effective electrical connection, resolving the contradiction between achieving good electrical contact and preventing harmful effects.
Solution Approach 2:
The patent applies beforehand cushioning by optimizing the anisotropic conductive film properties in advance to prevent metal line breakage and particle immersion during the hot-pressing process. The adjusted particle size and distribution create a cushioning effect that absorbs joining stress without damaging the metal lines or allowing particles to penetrate the substrate.
2Object-affected harmful factors
If hot-pressing pressure is reduced below 0.8 MPa to prevent metal line breakage, then less damage occurs, but the reliability of the joining process is reduced
Solution Approach 1:
The patent changes the hot-pressing parameters by optimizing pressure to 0.5-1.5 MPa and temperature to 150-210°C, which is different from the conventional 0.8 MPa. This parameter change allows effective joining while preventing metal line breakage, resolving the contradiction between maintaining joining reliability and preventing damage.
3Object-affected harmful factors
If hot-pressing temperature is reduced to prevent particle immersion, then less immersion occurs, but the anisotropic conductive film may be incompletely cured
Solution Approach 1:
The patent changes the hot-pressing temperature parameter to an optimized range of 150-210°C, which is slightly lower than conventional temperatures but sufficient for complete curing. This parameter change prevents conductive particle immersion into the plastic substrate while ensuring the anisotropic conductive film is completely cured, resolving the contradiction between preventing immersion and achieving complete curing.
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
This configuration enhances the reliability of flexible display panels by preventing metal line breakage and conductive particle immersion, ensuring stable electrical connections and improved performance.
Implementation Method 1
the anisotropic conductive film has an insulation film and a plurality of conductive particles disposed in the insulation film
Implementation Method 2
the hot-pressing pressure of the conventional joining process for joining the driving unit and the plastic substrate is about 0.8 MPa, and the hot-pressing temperature thereof is about 210 centigrade degrees
Data Source
AI summary
A flexible display panel comprises a flexible substrate, a display module, a driving unit and at least one anisotropic conductive film. The display module is disposed on the flexible substrate, and has a display area and a peripheral circuit area beside the display area. The anisotropic conductive film is connected between the peripheral circuit area and the driving unit, and the driving unit is electrically connected to the peripheral circuit area through the anisotropic conductive film. In addition, the anisotropic conductive film has an insulation film and a plurality of conductive particles disposed in the insulation film. Diameters of the conductive particles are in a range from 4.5 micrometers to 7 micrometers, and a distribution density of the conductive particles is a range from 45000 grains per square millimeter to 65000 grains per square millimeter. Therefore, the flexible display panel has high reliability.