Flexible Display Fabrication Using Segmented Substrates and Moisture Blocking
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Solution Overview
Problem
The development of flexible displays is hindered by challenges in fabrication, such as the difficulty in removing these displays from rigid carrier substrates without damaging them and the reduction in lifespan due to water vapor and oxygen penetration.
Innovation Solution
A method involving the sequential formation of layers on rigid carrier substrates, followed by precise cutting and assembly steps to separate the flexible substrates while forming a fill between the light emitting unit and the color filter layer, and applying an overcoat for moisture blocking, allowing the flexible display to be removed from the carrier substrates effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flexible displays are formed on rigid carrier substrates using sheet-to-sheet process, then the fabrication structure is established, but the surface processing and removal of flexible displays become challenging
Solution Approach 1:
The patent divides the flexible substrate into multiple segments by forming cutting lines that extend from edge to edge. This segmentation allows the flexible display to be easily separated from the rigid carrier substrate without damaging the display structure, resolving the contradiction between establishing a fabrication structure and enabling easy removal.
Solution Approach 2:
The patent performs preliminary cutting of the flexible substrate before final assembly, creating predetermined separation lines. This preliminary action facilitates subsequent surface processing and removal operations, making the entire manufacturing process easier to execute despite the complex multi-layer structure.
2Ease of manufacture
If flexible displays are removed from rigid carrier substrates, then the flexible display is obtained, but the lifespan is reduced due to water vapor and oxygen penetration
Solution Approach 1:
The patent uses a flexible substrate with controlled cutting lines that create a flexible shell structure. This flexible shell protects the internal components while allowing the display to be removed from the rigid carrier, maintaining reliability during operation. The flexible substrate itself acts as a barrier layer that prevents water vapor and oxygen penetration.
Solution Approach 2:
The patent introduces an encapsulation layer as an intermediary between the flexible substrate and the external environment. This encapsulation layer serves as a mediator that blocks water vapor and oxygen while allowing the flexible display to function, thus protecting the display components during removal and operation.
3Ease of operation
If precise cutting and assembly steps are performed to separate flexible substrates, then the flexible display can be removed from carrier substrates, but the fabrication process complexity increases
Solution Approach 1:
The patent applies segmentation by creating cutting lines that divide the flexible substrate into manageable sections. This segmentation simplifies the separation process from the rigid carrier substrate, making the fabrication process more controllable despite the multiple steps involved in precise cutting and assembly.
Data Source
AI summary
The invention provides a flexible display and method for fabricating the same. The flexible display includes: a first flexible substrate and an oppositely disposed second flexible substrate; a TFT layer and an emitting unit, sequentially formed on the first flexible substrate; a color filter layer and an overcoat formed on the second flexible substrate; a fill formed between the first flexible substrate and the second flexible substrate; and a dam formed between the first flexible substrate and the second flexible substrate and surrounding the fill.