Flexible Display Panel with Etching Stop Layers

Solution Overview

Problem

Conventional display panels using rigid glass substrates are prone to cracking due to inadequate compressive strengths and cannot be bent, limiting their application in flexible and slim form factors.

Innovation Solution

A flexible display panel is fabricated using flexible substrates with etching stop layers and active layers, allowing the glass substrates to be removed and replaced with flexible materials like plastic or metal substrates, enabling the panel to be bent and maintain a light and slim appearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of stationary object

If glass substrates are thinned to reduce weight and thickness, then the display panel becomes lighter and thinner, but the glass substrates become liable to cracking due to inadequate compressive strength

Engineering Contradiction:

Improveweight of glass substrateVSAvoidcompressive strength of glass substrate

Core Design Contradiction:

Weight of stationary objectVSStrength

Solution Approach 1:

The patent replaces rigid glass substrates with flexible substrates that can be made thinner without compromising structural integrity. The flexible substrate inherently tolerates deformation and bending, eliminating the cracking issue that plagues thinned glass substrates while achieving the desired weight and thickness reduction.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the material parameter from rigid glass to flexible material, fundamentally altering the mechanical properties. This parameter change enables the substrate to maintain adequate strength even at reduced thickness, as flexible materials have different stress distribution characteristics compared to glass.

Inventive Principle:

Principle #35Parameter changes

2Strength

If glass substrates are used to ensure adequate compressive strength, then the display panel has sufficient structural strength, but the display panel cannot be bent and is rigid

Engineering Contradiction:

Improvecompressive strength of substrateVSAvoidbendability of display panel

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent replaces rigid glass substrates with flexible substrates that can be made thinner without compromising structural integrity. The flexible substrate inherently tolerates deformation and bending, eliminating the cracking issue that plagues thinned glass substrates while achieving the desired weight and thickness reduction.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent transitions from a static rigid structure to a dynamic flexible structure that can adapt its shape. The flexible substrate allows the display panel to bend and deform without damage, enabling new form factors and applications while maintaining structural integrity through controlled deformation.

Inventive Principle:

Principle #15Dynamics

3Stability of the object's composition

If conventional glass substrates are used, then the display panel has adequate structural integrity, but alignment accuracy issues occur during fabrication

Engineering Contradiction:

Improvestructural integrity of display panelVSAvoidalignment accuracy during fabrication

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The patent replaces rigid glass substrates with flexible substrates that can be made thinner without compromising structural integrity. The flexible substrate inherently tolerates deformation and bending, eliminating the cracking issue that plagues thinned glass substrates while achieving the desired weight and thickness reduction.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the material parameter from rigid glass to flexible material, fundamentally altering the mechanical properties. This parameter change enables the substrate to maintain adequate strength even at reduced thickness, as flexible materials have different stress distribution characteristics compared to glass.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS9431467B2Flexible display panel comprising first and second etching stop layers and electro-optical device

Publication Date: 2016.08.30 AU OPTRONICS CORP

AI summary

A first etching stop layer and an active layer are formed on an inner surface of a first glass substrate, and a second etching stop layer and a cover layer are formed on an inner surface of a second glass substrate. A display media is formed between the first glass substrate and the second glass substrate. A first passivation layer is formed on an outer surface of the second glass substrate. A first etching process is performed to expose the first etching stop layer. A first flexible substrate is formed on the exposed first etching stop layer, and a second passivation layer is formed on the first flexible substrate. The first passivsation layer is removed. A second etching process is performed to expose the second etching stop layer. A second flexible substrate is formed on the exposed second etching stop layer, and the second passivation layer is removed.