Flexible Display Intermediate Layer for Sealant Adhesion
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Solution Overview
Problem
Flexible display devices face issues with non-uniform coating of side sealants due to differences in surface properties between the substrate, anisotropic conductive film layer, and flexible film, leading to potential delamination and cracking when subjected to external forces, which can result in device malfunction.
Innovation Solution
Incorporating an intermediate layer between the substrate and side sealant to ensure uniform coating and adhesion, using a material that can be crosslinked with both organic and inorganic materials to maintain consistent surface properties and enhance adhesion of the side sealant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If side sealant is applied directly on the substrate without an intermediate layer, then the manufacturing process is simpler, but the coating uniformity and adhesion are poor due to different surface properties of substrate, anisotropic conductive film layer, and flexible film
Solution Approach 1:
An intermediate layer is introduced between the side sealant and the substrate to serve as a mediator. This intermediate layer has surface properties that enable uniform coating of the side sealant, while its bottom surface can adhere to different materials including the substrate, anisotropic conductive film layer, and flexible film. The intermediate layer thus resolves the adhesion and coating uniformity issues caused by the heterogeneous surface properties of the underlying layers.
2Strength
If side sealant is applied directly on the substrate, then the device structure is simpler, but delamination and cracking occur when subjected to external forces
Solution Approach 1:
The intermediate layer acts as a buffer and mediator between the side sealant and the substrate assembly. When external forces are applied, the intermediate layer distributes these forces uniformly, preventing stress concentration that would lead to delamination and cracking. The intermediate layer's ability to adhere to both organic and inorganic materials ensures strong overall adhesion while maintaining structural integrity under mechanical stress.
3Reliability
If an intermediate layer is added between substrate and side sealant, then coating uniformity and adhesion are improved, but the device structure becomes more complex
Solution Approach 1:
The intermediate layer is designed as a functional mediator that provides multiple benefits: uniform coating surface for the side sealant, adhesion to heterogeneous underlying layers, and mechanical buffer against external forces. By consolidating these functions into a single layer with appropriate material properties, the design achieves improved reliability without excessive complexity increase.
Solution Approach 2:
The intermediate layer's material parameters are optimized to balance coating uniformity, adhesion strength, and mechanical flexibility. By adjusting the material composition and physical properties of the intermediate layer, the design achieves reliable performance while keeping the added structural complexity minimal and justified by the functional improvements.
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
The intermediate layer ensures uniform distribution and strong adhesion of the side sealant, preventing delamination and cracking, thus maintaining the integrity and functionality of the flexible display device under external forces.
Implementation Method 1
using a material that can be crosslinked with both organic and inorganic materials to maintain consistent surface properties and enhance adhesion of the side sealant
Data Source
AI summary
A flexible display device and method of manufacturing the same are provided. A flexible display device includes a display region and a non-display region, the display region including a plurality of pixels, the non-display region being outside the display region. The flexible display device further includes: a substrate, a side sealant covering at least part of the non-display region of the substrate, and an intermediate layer between the substrate and the side sealant.