Flexible Display Substrate Stack for Soot-Free Laser Separation
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Solution Overview
Problem
The challenge in manufacturing flexible display devices is the generation of a soot-like black substance during the separation of the glass substrate from the resin substrate, which affects light transmittance and image quality due to the deterioration of polyimide at the interface, leading to non-uniformity in liquid crystal display devices and reduced commercial value in organic EL display devices.
Innovation Solution
A multilayer structure comprising an adhesion layer, a silicon layer, and a gas block layer formed from nitride materials, or an aluminum oxide layer, is introduced between the resin substrate and the glass substrate to prevent gas-generated soot formation by blocking gases and maintaining adhesiveness, allowing for secure separation through stress-induced shrinkage during excimer laser irradiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser ablation is used to separate the glass substrate from the resin substrate, then the separation is achieved, but polyimide deteriorates and forms soot-like black substance at the interface
Solution Approach 1:
A silicon oxide layer is introduced as an intermediary between the glass substrate and the resin substrate. This layer acts as a buffer that absorbs the impact of laser ablation, preventing direct damage to the polyimide resin substrate while still allowing for effective separation of the glass substrate.
Solution Approach 2:
The silicon oxide layer is formed in advance on the glass substrate before the resin substrate is applied. This pre-formed layer serves as a protective cushion that prevents laser-induced soot formation during the separation process, eliminating the need for post-processing cleaning.
2Reliability
If many layers are formed on the resin substrate to achieve device functionality, then device performance is improved, but light transmittance decreases
Solution Approach 1:
The patent employs extremely thin film structures for various device components. The silicon oxide layer is formed with a thickness of 1-10 nm, and other layers such as the adhesion layer and functional layers are also optimized for minimal thickness while maintaining their protective and functional properties, thereby maximizing light transmittance.
Solution Approach 2:
The patent uses composite material structures combining different materials with complementary properties. The silicon oxide layer provides protection and laser resistance, while the adhesion layer ensures strong bonding. This composite approach allows each layer to be optimized for its specific function while maintaining overall light transmittance.
3Adaptability or versatility
If the resin substrate is made thin to achieve flexibility, then flexibility is improved, but adhesion to the glass substrate during manufacturing becomes more difficult
Solution Approach 1:
An adhesion layer is introduced as an intermediary between the glass substrate and the thin resin substrate. This layer has optimized chemical and physical properties that enable strong adhesion to both substrates, compensating for the reduced adhesion strength that would otherwise result from using a thinner resin substrate.
Solution Approach 2:
The patent employs a composite structure with multiple specialized layers including the adhesion layer and silicon oxide layer. Each layer is designed with specific material properties that collectively provide both strong adhesion during manufacturing and maintained flexibility in the final flexible display device.
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
This solution effectively prevents the formation of soot-like substances, maintains light transmittance, and ensures high-quality image display by stabilizing the adhesion and preventing polyimide deterioration during the separation process.
Implementation Method 1
a silicon layer, in which a gas block layer formed from nitride is formed on the silicon layer, is formed on the adhesion layer... allowing for secure separation through stress-induced shrinkage during excimer laser irradiation
Implementation Method 2
a gas block layer formed from nitride is formed on the silicon layer... to prevent gas-generated soot formation by blocking gases
Implementation Method 3
a first layer, in which a second layer, which is a separation layer, is formed on the first layer... stabilizing the adhesion
Data Source
AI summary
The purpose of the present invention is to prevent forming of soot like black substance on the back of the TFT substrate of resin during laser ablation to separate the glass substrate from the TFT substrate. The present invention takes the following structure to counter measure the above problem. A display device having pixels formed on a first surface of the resin substrate including: a first layer, formed from nitride, being formed on a second surface of the resin substrate, the second surface being an opposite surface to the first surface, in which a second layer, which is a separation layer, is formed on the first layer.