Flexible Display Etching Selectivity and Resin Barrier
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Solution Overview
Problem
The existing methods for manufacturing flexible display devices face challenges in process stability and production yield due to the deformation of flexible substrates under high temperatures and the risk of etchant intrusion during the substrate transcription process, which degrades the quality of display elements.
Innovation Solution
A method involving the formation of a flexible display device with a flexible substrate, a display element layer, and an insulating protective layer, where the etching selectivity of the rigid substrate is at least 20 times greater than that of the insulating protective layer, allowing for the selective removal of the rigid substrate without damaging the display elements, and the use of a resin barrier to prevent etchant intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible substrate is used to enable flexibility in display devices, then the display device can be rolled or folded, but the substrate deforms under high temperatures during manufacturing processes
Solution Approach 1:
The manufacturing process is divided into two separate stages: first forming display elements on a rigid glass substrate at high temperatures, then transferring the completed element layer to a flexible substrate. This segmentation allows each substrate to be used in its optimal temperature range, resolving the contradiction between flexibility and thermal stability.
Solution Approach 2:
The display elements are formed in advance on a rigid substrate that can withstand high temperatures, before the flexible substrate is introduced. This preliminary action on the rigid substrate eliminates the need for the flexible substrate to endure high-temperature processing, preventing deformation while maintaining final flexibility.
2Ease of manufacture
If the insulating protection layer is removed during substrate transcription, then the flexible substrate can be attached to display elements, but etchant intrudes and damages the display elements
Solution Approach 1:
The flexible substrate is attached to the display element layer before the glass substrate removal step. This preliminary attachment creates a protective configuration where the flexible substrate acts as a barrier, preventing etchant from reaching and damaging the display elements during the subsequent glass removal process.
Solution Approach 2:
The flexible substrate serves as an intermediary protective layer between the etchant and the display elements. By positioning the flexible substrate in this intermediate location, it mediates the interaction between the aggressive etchant and the sensitive display elements, allowing glass removal while protecting the elements from damage.
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 ensures the stability of the manufacturing process and increases production yield by protecting the display elements from etchant damage and allowing for the successful formation of flexible display devices with enhanced thermal resistance and structural integrity.
Implementation Method 1
the etching selectivity of the rigid substrate is at least 20 times greater than that of the insulating protective layer, allowing for the selective removal of the rigid substrate
Data Source
AI summary
A flexible display device and a method for manufacturing a flexible display are provided. The flexible display device includes a flexible substrate, a display element layer formed on the flexible substrate; an insulating protective layer covering the display element layer; and a rigid substrate. The rigid substrate has an etching selectivity at least 20 times greater than that of the insulating protective layer.