Flexible Display Panel Defect Repair via Laser Annealing
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Solution Overview
Problem
Laser separation technology in flexible display panel manufacturing often causes defects, affecting the display quality and yield of flexible display panels.
Innovation Solution
A defect repairing method involving a transparent substrate, forming a flexible substrate and array substrate layer, patterning the substrate with a laser, and annealing to repair defects, followed by forming organic light-emitting and encapsulating layers and separating the substrates using cutting or laser techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser separation technology is used to separate the flexible display panel from the glass substrate, then the separation process is efficient and automated, but laser irradiation causes defects on the flexible display panel affecting display quality
Solution Approach 1:
The patent divides the flexible substrate into two regions: a first region that is separated from the glass substrate using laser irradiation, and a second region that remains adhered to the glass substrate. This segmentation allows different processing methods to be applied to different regions, enabling efficient separation where needed while preserving quality in critical display areas.
Solution Approach 2:
The patent applies different treatments to different regions of the flexible substrate. The first region (non-display area) undergoes laser separation, while the second region (display area) maintains strong adhesion to the glass substrate to prevent defects. This local differentiation resolves the contradiction by applying efficiency-enhancing methods only where quality concerns are less critical.
2Speed
If high-energy ultraviolet laser is used for separation, then the separation process is fast and effective, but it causes thermal damage and defects on the flexible display panel
Solution Approach 1:
The patent segments the flexible substrate into a first region for laser separation and a second region for preservation. By limiting laser irradiation to only the first region, the harmful thermal effects are confined to non-critical areas while the second region remains undamaged, maintaining both speed and quality.
Solution Approach 2:
The patent strategically uses the harmful thermal effects of laser irradiation only in regions where they will not compromise display quality (the first region), while preserving the second region from such effects. This converts the potentially harmful laser energy into a beneficial separation tool for non-critical areas.
3Ease of manufacture
If the flexible substrate is completely separated from the glass substrate, then the manufacturing process is simplified, but stress and damage from thermal expansion mismatches occur in the array substrate layer
Solution Approach 1:
The patent implements partial separation where only the first region is detached from the glass substrate while the second region remains adhered. This segmented approach provides manufacturing flexibility while maintaining structural support in the display area, preventing stress and damage from thermal expansion mismatches.
Solution Approach 2:
The glass substrate acts as an intermediary support structure for the second region of the flexible substrate. By maintaining adhesion in the display area, the glass substrate continues to provide mechanical support and thermal stability, preventing damage while allowing process flexibility.
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 method quickly and easily repairs laser-induced defects, optimizing display quality and improving yield by reducing stress and damage from thermal expansion mismatches in the array substrate layer.
Implementation Method 1
annealing the transparent substrate on which the array substrate layer and the flexible substrate are formed
Implementation Method 2
reducing stress and damage from thermal expansion mismatches in the array substrate layer
Implementation Method 3
irradiating the display area with a pattered laser on the second surface
Implementation Method 4
separating the flexible substrate not blocked by the mask from the transparent substrate
Data Source
AI summary
The present disclosure provides a defect repairing method of a flexible display panel including: providing a transparent substrate, the transparent substrate including a first surface and a second surface opposite to each other; forming a flexible substrate on the first surface; forming an array substrate layer on the surface of the flexible substrate, wherein the array substrate layer includes a display area and a peripheral area; irradiating the display area with a patterned laser on the second surface; and annealing the transparent substrate on which the array substrate layer and the flexible substrate are formed. The defect repairing method of the flexible display panel can quickly and easily repair various defects caused by the laser irradiation of the flexible display panel so as to optimize the display effect of the flexible display panel and improve the yield of the flexible display panel.