Flexible Display Insulating Layer Recess Reinforcement
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Solution Overview
Problem
Flexible display devices face issues with exfoliation or damage to layers when a portion of the protective film is removed during manufacturing, particularly affecting insulating layers and the flexible substrate.
Innovation Solution
A flexible display device design that includes a reinforcing portion with a metallic material covering the slope surface of a recess in the insulating layer, which is melted and hardened using a laser beam to prevent exfoliation, and a protective film with an opening to expose a pad for testing, ensuring the integrity of the layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a protective film is removed to expose a pad for testing, then the pad becomes accessible for electrical testing, but the insulating layers and flexible substrate may exfoliate or damage
Solution Approach 1:
The insulating layer is designed with different local properties: a recess portion is formed only in the region where pad exposure is needed, while other regions maintain their original protective function. This localized modification allows pad access without compromising the overall integrity of the insulating layers and flexible substrate.
Solution Approach 2:
The recess portion is formed in the insulating layer before the protective film removal step. This preliminary action prepares the structure in advance, creating a controlled access path that prevents unexpected exfoliation or damage when the protective film is subsequently removed for pad exposure.
2Ease of manufacture
If the protective film is removed completely, then all underlying layers are exposed for inspection, but the insulating layers and flexible substrate become vulnerable to damage
Solution Approach 1:
Instead of removing the protective film completely or modifying the entire insulating layer, only a specific recess portion is formed where inspection access is required. This localized approach provides necessary inspection accessibility while maintaining the protective function in other regions, thereby reducing layer vulnerability.
3Ease of operation
If a recess is formed in the insulating layer to expose the pad, then the pad becomes accessible, but the insulating layer structure is weakened
Solution Approach 1:
The recess portion is formed with specific dimensional constraints and localized geometry that minimizes the impact on overall insulating layer strength. The recess is created only in the necessary region for pad access, preserving the structural integrity of the remaining insulating layer while achieving pad accessibility.
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 effectively prevents exfoliation of insulating layers and damage to the protective film and underlying layers, enhancing the reliability of the flexible display device during the manufacturing process.
Implementation Method 1
irradiating a laser beam at a portion of the insulating layer corresponding to the pattern portion to form a recess in the insulating layer and melt at least a part of the pattern portion
Data Source
AI summary
A method of manufacturing a display device including forming a display unit in a central area of a flexible substrate; forming a pattern portion comprising a metallic material in a peripheral area of the flexible substrate; forming an insulating layer covering the pattern portion; forming an encapsulation layer including at least one inorganic layer and at least one organic layer over the display unit; and irradiating a laser beam at a portion of the insulating layer corresponding to the pattern portion to form a recess in the insulating layer and melt at least a part of the pattern portion.