Flexible Display Panel Polymer Wall Spacer Design
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Solution Overview
Problem
Flexible display panels using spacers are prone to damage when bent, leading to light leakage due to relative movement between substrates, which compromises the display's strength and effectiveness.
Innovation Solution
Incorporating a liquid crystal display layer with polymer walls made of high macromolecule materials between the flexible substrates, arranged in a grid pattern to reduce relative movement and enhance bonding, and optionally including a touch layer with a metal mesh to minimize display loss and simplify manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If spacers are used to maintain the distance between flexible substrates, then the structural support is improved, but the damage during bending increases and light leakage occurs due to relative movement between substrates
Solution Approach 1:
The patent divides the spacer structure into multiple segments: a first spacer layer and a second spacer layer arranged in parallel. This segmentation allows each layer to independently bear mechanical stress during bending, preventing the single-layer spacers from breaking and causing light leakage. The segmented structure maintains structural support while improving reliability during flexing operations.
Solution Approach 2:
The patent employs composite spacer structures combining multiple spacer layers with different properties. The first and second spacers are arranged in parallel to form a composite structure that distributes mechanical stress, reducing the likelihood of breakage during bending while maintaining the necessary structural support between substrates.
2Reliability
If a complex multi-layer structure is implemented to improve display effectiveness, then the display quality is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent designs the first and second spacers to serve multiple functions: they maintain substrate distance, provide mechanical support during bending, and prevent relative movement between substrates. This multi-functionality reduces the need for additional specialized components, thereby improving display effectiveness without proportionally increasing manufacturing complexity.
Solution Approach 2:
The patent uses thin film spacer structures that are flexible and can be integrated into the existing manufacturing process. These thin film spacers maintain the necessary structural complexity for display effectiveness while being compatible with standard flexible display manufacturing techniques, thus not excessively increasing device complexity.
3Area of stationary object
If the aperture ratio is increased to improve display area, then the display area is improved, but the structural strength and stability during bending deteriorate
Solution Approach 1:
The patent transitions from a single-layer spacer structure to a multi-layer parallel spacer configuration. This dimensional change in the spacer architecture allows the spacers to distribute mechanical stress across multiple layers, maintaining structural strength and stability even when the aperture ratio is increased and individual spacer spacing is reduced.
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
The solution reduces damage to the substrates during bending, improves display effectiveness by maintaining strength and aperture ratio, and enriches the panel's functionality with touch control capabilities while lowering manufacturing costs.
Implementation Method 1
performing an irradiating and etching process to the base panel by using a mask provided with a grid pattern, to form a plurality of polymer walls on the first flexible substrate
Implementation Method 2
a liquid crystal display layer, a black matrix grid and a plurality of polymer walls that are located between the first flexible substrate and the second flexible substrate
Data Source
AI summary
A flexible display panel, a manufacturing method thereof and a display device are disclosed. The flexible display panel includes a first flexible substrate and a second flexible substrate which are cell-assembled with each other; and a liquid crystal display layer, a black matrix grid and a plurality of polymer walls which are located between the first flexible substrate and the second flexible substrate; the liquid crystal display layer is located in gaps of the plurality of polymer walls, and includes a plurality of liquid crystal pixel units arranged in an array; the plurality of liquid crystal pixel units are delimited by a projection of the black matrix grid on the liquid crystal display layer.