Flexible Display Edge Layer for Crack-Safe Press Cutting

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Solution Overview

Problem

Flexible displays face issues with crack generation and panel contraction during the cutting process, leading to potential failure of the thin film encapsulation layer and display failure.

Innovation Solution

A flexible display design featuring a crack suppressing layer made of organic material, such as UV curable or thermosetting resin, is applied on the inorganic layer at the edge of the flexible substrate to minimize crack propagation and protect the thin film encapsulation layer, which includes a barrier, buffer, gate insulating, and interlayer insulating layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a press cutting method is used to separate flexible displays, then manufacturing efficiency is improved, but cracks are generated in the inorganic layer and thin film encapsulation layer

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidcrack generation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A crack suppressing layer is formed on the inorganic layer before the cutting process. This layer acts as a preliminary protective measure that prevents cracks from propagating into the thin film encapsulation layer during the subsequent press cutting operation, thereby maintaining both manufacturing efficiency and product reliability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The crack suppressing layer functions as a cushioning layer that absorbs and distributes the stress generated during press cutting. By placing this layer beforehand on the inorganic layer, the harmful cutting forces are mitigated before they can cause damage to the encapsulation layers, resolving the contradiction between efficient cutting and crack prevention

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Speed

If strong press cutting force is applied, then cutting speed is improved, but crack propagation to the thin film encapsulation layer increases

Engineering Contradiction:

Improvecutting speedVSAvoidcrack propagation

Core Design Contradiction:

SpeedVSObject-affected harmful factors

Solution Approach 1:

The crack suppressing layer serves as an intermediary between the inorganic layer and the thin film encapsulation layer. During high-speed press cutting, this intermediate layer absorbs the harmful forces and prevents them from reaching the encapsulation layers, allowing fast cutting without crack propagation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The crack suppressing layer is designed as a sacrificial element that may be damaged or removed during cutting, but in doing so protects the more valuable thin film encapsulation layer. This disposable layer enables high-speed cutting while preserving the integrity of the functional display layers

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUSRE49770E1Flexible display having a crack suppressing layer

Publication Date: 2023.12.26 SAMSUNG DISPLAY CO LTD

AI summary

A flexible display may suppress a generation of cracks in an inorganic layer and suppress the spread of cracks. A flexible display includes a flexible substrate and an inorganic layer formed on the flexible substrate. A display unit is formed on the inorganic layer. The display unit includes a plurality of pixels. Each pixel includes an organic light emitting diode. A thin film encapsulation layer covers the display unit. A crack suppressing layer is formed along the edge of the flexible substrate. The crack suppressing layer is disposed on the inorganic layer at an exterior side of the thin film encapsulation layer.