Flexible Display Panel Corner Structure with Barrier Layer
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Solution Overview
Problem
The manufacturing process of flexible display panels is challenging due to the flexibility of substrates, which can lead to issues like peeling and deformation during the formation of corner display areas, affecting the structural integrity and display quality.
Innovation Solution
A display panel design with a substrate featuring a front display area, corner display areas with extension and auxiliary areas, and a barrier layer to prevent peeling and deformation, along with a method of manufacturing that includes forming pattern layers and separating the substrate from a support substrate to ensure proper alignment and attachment of display elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible substrate is used to implement bent corner display areas, then the display area can be expanded and various curvatures can be achieved, but the substrate becomes difficult to handle during manufacturing and may peel or deform
Solution Approach 1:
A support substrate is introduced as an intermediary carrier during the manufacturing process. The flexible substrate is formed on this rigid support substrate, which provides mechanical stability and ease of handling. After the display elements are formed, the flexible substrate is separated from the support substrate, allowing the final flexible display product to be obtained while having benefited from the manufacturing advantages of the support substrate throughout the fabrication process.
Solution Approach 2:
The flexible substrate is pre-formed on the support substrate before the actual display element fabrication begins. This preliminary positioning and support setup ensures that the flexible substrate is properly aligned and stabilized prior to subsequent manufacturing steps, preventing deformation and peeling during the formation of corner display areas and other critical structures.
2Productivity
If the flexible substrate is formed directly without support, then the final flexible product is obtained, but peeling and deformation occur during the manufacturing process
Solution Approach 1:
The support substrate serves as a temporary intermediary that provides mechanical strength and stability during manufacturing. This intermediary structure prevents peeling and deformation of the flexible substrate while maintaining manufacturing efficiency, as all standard fabrication processes can be performed without special handling precautions.
Solution Approach 2:
The support substrate provides beforehand cushioning and mechanical protection to the flexible substrate during the manufacturing process. This pre-established support system prevents potential damage from peeling and deformation before they can occur, ensuring substrate stability throughout the fabrication of display elements and corner structures.
3Reliability
If corner display areas are formed with extension and auxiliary areas, then peeling and deformation are prevented, but the substrate structure becomes more complex
Solution Approach 1:
The corner display area is segmented into distinct functional zones: an extension area that provides gradual transition and stress distribution, and auxiliary areas that provide additional support and anchoring. This segmentation allows each zone to perform its specific function in preventing peeling and deformation, while the overall structure remains manageable through clear functional division.
Solution Approach 2:
Different regions of the substrate are given different structural qualities - the extension area has a specific geometry for stress distribution, while the auxiliary areas provide localized support. This local quality differentiation ensures that each part of the corner display area contributes optimally to preventing peeling and deformation, enhancing structural integrity without requiring uniform complexity throughout the entire substrate.
Data Source
AI summary
A display panel includes: a substrate including a front display area, and a corner display area at a corner of the display panel; and a display element at the corner display area. The corner display area includes: a first extension area extending in a direction away from the front display area; and a first auxiliary area connected to the first extension area, and extending in a direction away from the front display area. The substrate includes a base layer, and a barrier layer on the base layer, the base layer overlapping with the first extension area and the first auxiliary area, and the barrier layer overlapping with the first extension area and spaced from the first auxiliary area.