Flexible Display Array Substrate Crack Prevention Design
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Solution Overview
Problem
Flexible display devices face issues with cracks and shrinkage during the cutting process due to the tearing of testing wires, which can lead to defects and damage to the thin-film layers and encapsulation units.
Innovation Solution
An array substrate design that includes a crack preventing unit formed in the non-display region between the edge of the encapsulation unit and the edge of each display unit, which is electrically connected to the testing wires and separates the display units, preventing the propagation of cracks and reducing the likelihood of damage during cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If testing wires are formed between adjacent display units for electrical connection, then electrical connectivity is improved, but cracks and shrinkage occur during cutting process
Solution Approach 1:
The patent divides the array substrate into multiple individual display units by forming cutting lines that separate adjacent display units. The testing wires are positioned within wire regions that are segmented from the display regions, allowing individual cutting of each display unit while maintaining electrical connectivity through the testing wires during the cutting process.
Solution Approach 2:
The patent introduces a buffer layer as an intermediary element between the display units and the testing wires. This buffer layer provides mechanical support and stress distribution during the cutting process, preventing cracks from propagating from the testing wires to the display units while maintaining electrical connectivity.
2Productivity
If multiple display units are formed on a mother substrate for mass production, then productivity is improved, but cracks propagate between display units during cutting
Solution Approach 1:
The patent segments the array substrate into multiple display units arranged on a mother substrate, with cutting lines defined between adjacent display units. The wire regions containing testing wires are also segmented and positioned separately from the display regions, allowing clean separation during cutting while maintaining electrical connectivity before cutting.
Solution Approach 2:
The patent extracts the testing wires from the display regions and places them in separate wire regions between adjacent display units. This separation allows the testing wires to be removed or cut along with the buffer layer during the cutting process, preventing crack propagation to the display units while maintaining productivity through mass production on the mother substrate.
3Ease of operation
If cutting lines are formed to individually divide display units, then ease of operation is improved, but cracks occur at the edges of display units
Solution Approach 1:
The patent introduces a buffer layer as an intermediary between the display units and the cutting lines. This buffer layer absorbs mechanical stress and prevents cracks from forming at the edges of the display units during the cutting process, while still allowing individual separation of display units along the cutting lines.
Solution Approach 2:
The buffer layer is formed beforehand in the regions where cutting lines will be created, providing pre-cushioning against crack formation. This layer is strategically positioned to intercept and absorb cutting stresses before they can propagate to the display unit edges, ensuring edge integrity during individual unit separation.
Data Source
AI summary
An array substrate for a flexible display device, the array substrate including a mother substrate, a plurality of display units separated on the mother substrate, in which the plurality of display units include display regions that display images and non-display regions that extend from the display regions to edges of each of the plurality of display units, respectively, encapsulation units covering the display regions of the plurality of display units, respectively, a plurality of testing wires in a wire region between adjacent display units from among the plurality of display units, in which the plurality of testing wires are electrically connected to each of the plurality of display units, and crack preventing units in the non-display regions between edges of the encapsulation units and the edges of each of the plurality of display units, respectively.