Flexible Display Layer Transfer for Repeated Bending Reliability
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Solution Overview
Problem
Existing display devices using organic electroluminescence (EL) elements face challenges in achieving high reliability, flexibility, and durability, particularly in repeated bending applications, with a need for improved resistance to bending and manufacturing methods that enhance yield, productivity, and reduce thickness and cost.
Innovation Solution
A method involving the formation of a separation layer over a support substrate, followed by an inorganic insulating layer with distinct portions, where a display element and connection electrode are formed, allowing for separation and transfer to a flexible substrate, with etching using the substrate as a mask to expose the connection electrode, utilizing materials and processes that ensure high yield and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a display device is designed to be flexible with small bending radius, then adaptability and flexibility are improved, but reliability and resistance to repeated bending deteriorate
Solution Approach 1:
The patent divides the display device into multiple functional layers (substrate layer, buffer layer, insulating layers, conductive layers, sealing layer) that can independently accommodate bending stress. This segmentation allows each layer to be optimized for its specific mechanical and electrical functions, enabling the overall device to flex without compromising reliability.
Solution Approach 2:
The patent employs flexible substrate materials and thin-film structures throughout the display device construction. The use of thin flexible substrates and thin-film deposited layers (insulating films, conductive films) enables the device to achieve small bending radii while maintaining structural integrity and reliability through repeated bending cycles.
2Weight of moving object
If the display device structure is simplified to reduce thickness, then weight and thickness are reduced, but manufacturing precision and reliability may deteriorate
Solution Approach 1:
The patent achieves weight reduction through the use of thin-film structures for all functional layers. Thin insulating films, thin conductive films, and thin sealing layers are deposited using vapor deposition techniques, maintaining the necessary functional precision while minimizing thickness and weight.
Solution Approach 2:
The patent employs composite material structures combining organic and inorganic materials in specific layer configurations. The buffer layer uses organic insulating material, while other layers use inorganic materials deposited as thin films. This composite approach optimizes both mechanical properties for flexibility and electrical properties for functionality, achieving high manufacturing precision in thin structures.
3Ease of manufacture
If conventional manufacturing methods are used for flexible display devices, then ease of manufacture is maintained, but productivity and manufacturing yield deteriorate
Solution Approach 1:
The patent merges multiple manufacturing operations into integrated process steps. Buffer layers, insulating layers, and conductive layers are formed using vapor deposition techniques that can deposit multiple materials sequentially in the same chamber without breaking vacuum, combining what would traditionally be separate deposition processes into one continuous operation, thereby improving productivity and yield.
Solution Approach 2:
The patent employs vapor deposition equipment that can deposit multiple types of materials (organic and inorganic insulating materials, conductive materials) using the same fundamental process. This multi-functional capability allows a single manufacturing line to produce all layers of the flexible display device, improving manufacturing efficiency and yield while maintaining ease of operation.
Data Source
AI summary
A flexible display device is manufactured with high yield. A display device having high resistance to repeated bending is provided. The display device is manufactured by forming a separation layer over a support substrate; forming, over the separation layer, an inorganic insulating layer including a first portion and a second portion; forming a display element over the inorganic insulating layer to be overlapped with the first portion; forming a connection electrode over the inorganic insulating layer to be overlapped with the second portion; sealing the display element; separating the support substrate and the inorganic insulating layer using the separation layer; attaching a substrate to the inorganic insulating layer to be overlapped with the first portion; and etching the second portion using the substrate as a mask to expose the connection electrode.