Flexible Display Graphene Adhesive Separation and Barrier Formation
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Solution Overview
Problem
Current methods for manufacturing flexible display devices face challenges in efficiently separating the flexible substrate from the carrier substrate without damaging the display element part and ensuring reliable barrier layer formation on both surfaces.
Innovation Solution
A method involving the formation of a graphene adhesive layer with alternating electrically charged graphene oxide layers on a carrier substrate, followed by the deposition of a flexible substrate and subsequent separation using an external force, with a silicon oxycarbide-based barrier layer formed on the exposed surface to prevent defects and enhance reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a graphene adhesive layer with alternating electrically charged graphene oxide layers is formed on the carrier substrate, then the separation of the flexible substrate from the carrier substrate can be achieved without damaging the display element part, but the manufacturing process complexity increases due to the multi-layer structure formation
Solution Approach 1:
The adhesive layer is segmented into multiple graphene oxide sub-layers with alternating electric charges, creating a structured multi-layer configuration that enables controlled separation while maintaining integrity of the display element part
Solution Approach 2:
The graphene oxide layers with alternating electric charges act as an intermediary between the carrier substrate and flexible substrate, providing a controlled interface that facilitates clean separation without damaging the display element part
2Reliability
If a double-layer barrier including silicon oxycarbide is formed on the flexible substrate after separation, then the barrier reliability is improved and defects are prevented, but the manufacturing time and process steps increase
Solution Approach 1:
The first barrier layer is formed on the flexible substrate before separation from the carrier substrate, and the second barrier layer is formed after separation, ensuring both layers are in place before final device completion, which prevents defects and ensures reliability
Solution Approach 2:
The barrier layer composition is changed by incorporating silicon oxycarbide material, which provides superior barrier properties compared to conventional single-layer barriers, thereby improving reliability despite additional process steps
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 allows for the reliable separation of the flexible substrate from the carrier substrate without damaging the display element and provides improved mechanical properties and reduced manufacturing costs by forming a double-layer barrier on a single flexible substrate.
Implementation Method 1
a first graphene oxide layer charged with a first electric charge is formed. A second graphene oxide layer is formed on the first graphene oxide layer. The second graphene oxide layer is charged with a second electric charge opposite to the first electric charge.
Implementation Method 2
the graphene adhesive layer is formed through chemical vaporization deposition
Data Source
AI summary
A method of manufacturing a flexible display device includes forming a graphene adhesive layer on a carrier substrate, forming a flexible substrate on the graphene adhesive layer, forming a first barrier layer on the flexible substrate, forming a display element part on the first barrier layer, forming a protective film on the display element part, separating the flexible substrate from the carrier substrate, removing a remaining portion of the graphene adhesive layer from a surface of the flexible substrate, and forming a second barrier layer on the surface of the flexible substrate, after removing the remaining portion of the graphene adhesive layer from the surface of the flexible substrate.