Flexible Display Mounting via Segmented Base Material and Protective Film
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Solution Overview
Problem
In the manufacturing of flexible display devices, such as organic electroluminescence (EL) displays, the mounting of components like driver ICs is prone to failure due to the lack of support from a substrate, especially when higher loads are involved.
Innovation Solution
A method involving a base material with a resin, where components are mounted using an adhesive material and a pressure-sensitive adhesive layer, with a protective film stacked on the opposite side, and a contact portion of a head is housed within an exposed area to ensure direct contact and secure mounting without a support substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the base material is separated from the support substrate to enable component mounting, then mass productivity is improved, but mounting failure rate increases due to lack of support
Solution Approach 1:
The patent divides the base material into two distinct regions: a supported region where the support substrate remains attached to provide mechanical strength, and an unsupported region where components are mounted. This segmentation allows the base material to be handled and mounted without full support, improving productivity while preventing mounting failures through localized support.
Solution Approach 2:
The patent applies different structural qualities to different regions of the base material. The supported region maintains attachment to the support substrate for mechanical stability during mounting, while the unsupported region allows free access for component placement. This local differentiation resolves the contradiction between needing support for reliability and needing accessibility for productivity.
2Reliability
If the base material is fully supported by a support substrate, then mounting reliability is improved, but handling flexibility and mass productivity deteriorate
Solution Approach 1:
The patent segments the support structure into a supported region with support substrate attachment and an unsupported region without attachment. This allows the base material to maintain sufficient mechanical reliability in the supported region while enabling flexible handling and efficient component mounting in the unsupported region, thereby improving mass productivity.
Solution Approach 2:
The patent creates a dynamic mounting structure where the base material transitions from a fully supported rigid state to a partially supported flexible state. The supported region provides necessary mechanical stability, while the unsupported region allows for flexible handling and efficient component mounting processes, improving overall productivity.
3Object-affected harmful factors
If a protective film is stacked on the entire base material, then protection is improved, but mounting precision deteriorates due to stress relaxation
Solution Approach 1:
The patent segments the protective film coverage to exclude the component mounting region. The protective film is applied only to regions not requiring precise component mounting, thereby maintaining protection benefits while eliminating stress relaxation effects that would compromise mounting precision in the exposed mounting region.
Solution Approach 2:
The patent applies different protective qualities to different regions: the protective film provides protection in non-mounting areas, while the exposed mounting region maintains stress-free conditions for precise component placement. This local differentiation resolves the contradiction between protection and mounting precision.
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 suppresses mounting failures, enhances yield, and improves connection reliability by efficiently utilizing the pressure from the heads and eliminating stress relaxation from the adhesive layer.
Implementation Method 1
stacking a protective film via a pressure-sensitive adhesive layer on the other side of the base material
Implementation Method 2
placing a component via an adhesive material on one side of a base material
Data Source
AI summary
A method of manufacturing a display device according to an embodiment of the present invention includes: placing a component via an adhesive material on one side of a base material containing a resin and having display area; stacking a protective film via a pressure-sensitive adhesive layer on the other side of the base material; and mounting the component on the base material by sandwiching and pressurizing the base material and the component using a pair of heads. An exposed portion in which no protective film is stacked is formed on the other side of the base material and is provided in correspondence with an area in which the component is provided, and one of the pair of heads has a contact portion, and the contact portion is housed within the exposed portion of the base material and the contact portion is brought into direct contact with the base material.