Flexible Display Fabrication Using Multi-Strength Adhesive Layer
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Solution Overview
Problem
The challenge in fabricating flexible display devices is the peeling apart of substrates during the manufacturing process due to the adhesive used between rigid and flexible substrates, which limits the application and flexibility of these devices.
Innovation Solution
A method involving an adhesive layer with multiple adhesive materials of varying strengths is employed, where a first adhesive material with high strength is used for the rigid substrate, a second with lower strength for the flexible substrate, and a third with higher strength at the edge to prevent peeling, along with passivation films and jig substrates to stabilize the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single adhesive material is used between rigid and flexible substrates, then the adhesion is uniform, but the substrate peels apart during the fabricating process
Solution Approach 1:
The patent applies local quality by using different adhesive materials with different adhesive strengths at different locations on the support film. The first adhesive material with high adhesive strength is used at the first surface where the rigid substrate is adhered, while the second adhesive material with lower adhesive strength is used at the second surface where the flexible substrate is adhered. This localized differentiation of adhesive properties prevents peeling during fabrication while maintaining reliable adhesion.
Solution Approach 2:
The patent employs composite materials by combining multiple adhesive materials with different adhesive strengths in a single adhesive layer structure. The first adhesive material and second adhesive material are applied as separate layers on opposite surfaces of the support film, creating a composite adhesive system that provides both strong adhesion for the rigid substrate and controlled adhesion for the flexible substrate, preventing peeling during the fabrication process.
2Manufacturing precision
If a rigid substrate is adhered to provide support for precise electrode formation, then the display part gains structural support, but the adhesive can come apart during fabrication
Solution Approach 1:
The patent applies local quality by positioning the first adhesive material with high adhesive strength specifically at the first surface of the support film where the rigid substrate is adhered. This localized high-strength adhesion ensures both precise electrode formation on the rigid substrate and reliable bonding that prevents the adhesive from coming apart during subsequent fabrication processes.
3Reliability
If the adhesive strength is increased to prevent peeling, then substrate adhesion is improved, but the flexible substrate cannot be detached when needed
Solution Approach 1:
The patent applies local quality by using the second adhesive material with lower adhesive strength at the second surface of the support film where the flexible substrate is adhered. This localized lower-strength adhesion allows the flexible substrate to be securely attached during fabrication while enabling easy detachment when needed, without compromising the strong adhesion of the rigid substrate at the first surface.
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 effectively prevents substrate peeling during the fabrication of flexible display devices, enhancing process stability and productivity by ensuring secure adhesion and easy peeling, thus enabling the production of flexible and stable display devices.
Implementation Method 1
adhering a rigid substrate to the first adhesive material
Implementation Method 2
adhering a flexible substrate onto the second and third adhesive materials
Implementation Method 3
a third adhesive material encompassing an edge of the second adhesive material such that an adhesive strength of the third adhesive material is higher than the adhesive strength of the second adhesive material
Data Source
AI summary
A fabricating method of a flexible display device includes the steps of providing an adhesive layer including a first adhesive material on a first surface of a support film, a second adhesive material on a second surface of the support film such that an adhesive strength of the second adhesive material is lower than an adhesive strength of the first adhesive material, and a third adhesive material encompassing an edge of the second adhesive material such that an adhesive strength of the third adhesive material is higher than the adhesive strength of the second adhesive material; a first passivation film adhered to the first surface of the support film with the first adhesive material therebetween; and a second passivation film adhered to the second surface of the support film with the second adhesive material and the third adhesive material therebetween; peeling the first passivation film from the adhesive layer; adhering a rigid substrate to the first adhesive material; peeling the second passivation film from the adhesive layer; and adhering a flexible substrate onto the second and third adhesive materials.