Flexible Display Adhesive with Reflective Layer for Laser Trimming
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Solution Overview
Problem
In display devices with flexible counter-substrates, trimming the substrate to expose terminal portions for external circuit connections is challenging due to the risk of damaging the array substrate and increasing signal line resistance, especially when using laser cutting, which also complicates the removal of edge portions and affects manufacturing efficiency.
Innovation Solution
Incorporating a reflective material within the adhesive layer on the array substrate to reflect laser light during cutting, thereby protecting the substrate and reducing signal line resistance by maintaining the integrity of the terminal portion connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser light is used to trim the flexible counter-substrate, then the counter-substrate can be cut, but the array substrate may be damaged due to the thin electro-optical layer
Solution Approach 1:
A resin layer is introduced as an intermediary protective layer between the array substrate and the laser cutting path. This resin layer absorbs the laser energy and prevents direct irradiation of the array substrate, thereby protecting it from damage while still allowing the counter-substrate to be trimmed effectively
Solution Approach 2:
The resin layer is applied in advance on the array substrate before the laser trimming process. This pre-applied layer acts as a cushion that absorbs the harmful laser energy, preventing it from reaching and damaging the array substrate during the counter-substrate trimming operation
2Object-affected harmful factors
If a metal layer is formed on the array substrate to reflect laser light, then the array substrate is protected, but the apparent resistance of signal lines is increased due to coupling
Solution Approach 1:
The resin layer serves as an intermediary that absorbs laser energy without requiring a metal reflective layer. This eliminates the coupling between metal and signal lines, thereby maintaining low apparent resistance and good signal transmission quality while still protecting the array substrate from laser damage
Solution Approach 2:
The solution replaces the metal layer reflection mechanism with a resin layer absorption mechanism. Instead of using metal to reflect laser light (which causes electrical coupling), the resin layer absorbs the laser energy, eliminating the harmful coupling effect while providing protection
3Ease of manufacture
If the counter-substrate is trimmed with laser light, then the counter-substrate can be cut, but the number of manufacturing steps is increased
Solution Approach 1:
The resin layer application is combined with the existing adhesive application process. The resin and adhesive are applied simultaneously in one step, eliminating the need for separate resin application and curing steps, thereby reducing manufacturing complexity while still providing laser protection
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 approach effectively prevents damage to the array substrate during cutting, maintains signal integrity by minimizing resistance in signal lines, and simplifies the removal of edge portions, enhancing manufacturing efficiency and display device performance.
Implementation Method 1
Incorporating a reflective material within the adhesive layer on the array substrate to reflect laser light during cutting, thereby protecting the substrate
Data Source
AI summary
According to one embodiment, a display device includes a first substrate, a second substrate, an adhesive, an electro-optical layer, a terminal portion, and a reflective material. The first substrate is attached to the second substrate with the adhesive. The terminal portion is provided in the first substrate. The reflective material contains in the adhesive. The second substrate has flexibility. The terminal portion is provided on an external side in comparison with the adhesive as seen in plan view.