Flexible Display Substrate Segmentation for Bending
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Solution Overview
Problem
Current display technologies face challenges in achieving sufficient flexibility and durability, particularly in the development of bendable and rollable display apparatuses, as they often suffer from structural limitations that hinder their ability to maintain functionality under external forces without cracking.
Innovation Solution
A method of manufacturing a display apparatus involving a carrier substrate with inorganic pattern layers, a substrate layer, and an encapsulation layer, where the substrate layer is separated from the carrier substrate using a laser beam, and the display apparatus includes a penetration-opening design that allows for flexibility and protection against external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid substrate structure is used to maintain structural stability, then the display apparatus can maintain its shape and protect internal components, but the flexibility and bendability of the display apparatus are reduced
Solution Approach 1:
The substrate is divided into a first substrate and a second substrate that can move relative to each other. The first substrate includes a display area where pixel units are arranged, while the second substrate includes a connection area. This segmentation allows the display area to maintain structural stability for protecting internal components, while the connection area provides flexibility for bending and rolling through relative movement between substrates.
Solution Approach 2:
The patent introduces a dynamic structure where the second substrate can move relative to the first substrate along a moving direction. This dynamic design enables the display apparatus to transition between different states (flat, bent, rolled) while maintaining pixel integrity in the display area, thus achieving both structural stability and flexibility.
2Adaptability or versatility
If the substrate layer is made thin to improve flexibility, then the display apparatus can bend and roll more easily, but the durability and resistance to cracking are reduced
Solution Approach 1:
By dividing the substrate into multiple layers (first substrate and second substrate), the patent achieves flexibility through relative movement between segments rather than relying on a single thin layer. This allows each substrate layer to maintain sufficient thickness for durability while the overall structure achieves bending capability through inter-layer movement.
Solution Approach 2:
The dynamic movement mechanism between substrates allows the display apparatus to achieve flexibility without requiring excessively thin substrate layers. The controlled relative movement absorbs bending stresses, preventing crack formation even when substrate layers maintain adequate thickness for structural integrity.
3Manufacturing precision
If a fixed substrate structure is used to maintain pixel alignment, then the display quality is preserved, but the ability to bend and roll without cracking is reduced
Solution Approach 1:
The patent segments the substrate such that the first substrate contains the display area with pixel units that maintain fixed alignment, while the second substrate contains the connection area that provides bending capability. This segmentation allows pixel alignment to be preserved in the display area while enabling bendability through the connection area's relative movement.
Solution Approach 2:
The dynamic design allows the connection area to move relative to the display area during bending and rolling operations. This dynamic movement is controlled to maintain pixel alignment in the display area while accommodating the mechanical deformation required for flexibility, thus preserving display quality during shape changes.
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 approach enhances the flexibility and durability of the display apparatus, enabling it to bend and roll while maintaining pixel integrity and reducing the risk of cracking, thus improving its overall performance and usability.
Implementation Method 1
The separating the substrate layer may include irradiating a laser beam to a rear surface of the carrier substrate and separating the substrate layer from the carrier substrate
Data Source
AI summary
A method of manufacturing a display apparatus includes preparing a carrier substrate including a display area, a connection area, a dummy area, and a cut area, forming inorganic pattern layers in the display area or the connection area of the carrier substrate, forming a substrate layer on the inorganic pattern layers, forming a first insulating layer on the substrate layer, removing the first insulating layer and the substrate layer arranged in the cut area, and separating the substrate layer from the carrier substrate. The inorganic pattern layers overlap at least one of the display area and the connection area.