Flexible Display Barrier Layer Laser Separation
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Solution Overview
Problem
Conventional methods for fabricating flexible display devices using plastic substrates require an additional process for forming a separation layer between the plastic and carrier substrates, increasing processing time and expense.
Innovation Solution
A method that eliminates the need for a separation layer by using a barrier layer on the plastic substrate, allowing for the separation of the carrier substrate through laser irradiation of the barrier layer, thereby simplifying the fabrication process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separation layer is formed between the plastic substrate and carrier substrate, then the carrier substrate can be separated from the flexible substrate, but the processing time and manufacturing cost increase
Solution Approach 1:
The patent combines the barrier layer (which prevents moisture penetration) with the separation layer (which enables laser-based separation) into a single integrated layer. This eliminates the need for a separate formation process for the separation layer, reducing manufacturing steps and processing time while maintaining both moisture protection and separation functionality
Solution Approach 2:
The barrier layer is designed to serve multiple functions: it acts as both a moisture barrier and a separation layer that can be selectively removed by laser irradiation. This multi-functional approach eliminates the need for dedicated separation layer materials and processes, streamlining the manufacturing workflow
2Ease of manufacture
If a separation layer is formed between the plastic substrate and carrier substrate, then the carrier substrate can be separated from the flexible substrate, but the manufacturing cost increases
Solution Approach 1:
The patent merges the barrier layer and separation layer into one integrated structure, reducing the number of fabrication steps. This simplification directly lowers manufacturing complexity and associated costs while maintaining the necessary functionality for both moisture protection and substrate separation
3Adaptability or versatility
If a plastic substrate is used instead of a glass substrate, then the display device becomes flexible, but the substrate is prone to damage during processing
Solution Approach 1:
The patent applies the adhesive layer to the carrier substrate before laminating the flexible plastic substrate. This preliminary action ensures proper positioning and bonding of the flexible substrate before subsequent processing steps, preventing misalignment and potential damage that could occur with improper handling of the flexible material
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 reduces processing time and cost by directly separating the carrier substrate from the flexible substrate without the need for a separation layer, facilitating the production of flexible display devices.
Implementation Method 1
separating the carrier substrate from the flexible substrate by irradiating a laser beam onto the barrier layer
Implementation Method 2
separating the carrier substrate from the flexible substrate by irradiating a laser beam onto the barrier layer
Data Source
AI summary
A method of fabricating a flexible display device, the method including applying a transparent adhesive layer on a carrier substrate, laminating a flexible substrate comprising a barrier layer on the transparent adhesive layer, forming a thin film transistor array on the flexible substrate, and separating the carrier substrate from the flexible substrate by irradiating a laser beam onto the barrier layer.