Flexible Display Separation via Release Layer and Asymmetric Cutting
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Solution Overview
Problem
Existing manufacturing methods for flexible display devices often result in breakage or damage when separating the flexible substrate and display panel from the supporting substrate during the manufacturing process.
Innovation Solution
A method involving the deposition of a separate layer on the supporting substrate, cutting the display panel and substrate to specific shapes with stepped incision surfaces, and using a peeling mechanism to separate the layers, ensuring minimal damage and efficient separation by controlling surface roughness and absorption forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flexible substrate is deposited on a supporting substrate for manufacturing, then the display panel can be formed through thin film processes, but the flexible substrate and display panel are prone to breakage or damage when separating from the supporting substrate
Solution Approach 1:
The patent introduces a separate layer between the flexible substrate and the supporting substrate, dividing the structure into distinct segments. This separate layer acts as a release layer that can be selectively removed, allowing the flexible substrate and display panel to be separated from the supporting substrate without causing breakage or damage during the manufacturing process
Solution Approach 2:
The separate layer serves as an intermediary component between the flexible substrate and the supporting substrate. This intermediate layer facilitates easy separation by providing a controlled interface that can be removed without damaging the flexible substrate or display panel, thus maintaining their integrity while enabling manufacturing on the supporting substrate
2Device complexity
If the supporting substrate and separate layer are cut with the same shape as the display panel, then the cutting process is simplified, but air traps and adherence issues occur during separation
Solution Approach 1:
The patent makes the supporting substrate and separate layer larger than the display panel, creating an asymmetric configuration. This asymmetry allows the edges of the supporting substrate and separate layer to extend beyond the display panel boundaries, preventing air traps and adherence issues during separation while maintaining a relatively simple cutting process
Solution Approach 2:
The patent addresses the separation issue by extending the supporting substrate and separate layer in the horizontal dimension beyond the display panel boundaries. This dimensional extension provides additional separation area that prevents air traps and adherence problems without significantly complicating the cutting process
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
Prevents breakage and damage during the separation process, maintaining the integrity of the flexible display device components and reducing the inferiority rate, while also minimizing air traps and adherence issues.
Implementation Method 1
depositing a separate layer on a supporting substrate
Implementation Method 2
depositing a display panel on the separate layer
Data Source
AI summary
A method of manufacturing a flexible display device, the method including depositing a separation layer on a supporting substrate; depositing a display panel on the separation layer; cutting the display panel to have a predetermined shape; cutting the supporting substrate and the separation layer to have a wider area than an area where the display panel, that is cut with the predetermined shape, contacts the supporting substrate and the separate layer; and separating the separate layer and the display panel from each other.