Flexible Display Panel Supporting Layer Sagging Prevention
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Solution Overview
Problem
Plastic LCD panels face sagging issues during manufacturing, leading to defects and increased costs when thicker films are used to prevent sagging, while thinner films result in substrate instability and potential damage to gate circuit parts.
Innovation Solution
A display panel design incorporating a flexible substrate with a supporting layer and sealant, where the supporting layer covers both the display and peripheral areas, with openings for the sealant to prevent sagging and protect the gate circuit, using materials like polyethyleneterephthalate (PET) resin and polymethylmethacrylate (PMMA) resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a thinner plastic film is used to reduce weight and thickness, then the plastic LCD apparatus achieves light weight, thin thickness, and superior flexibility, but the plastic film sags after being stripped from the carrier substrate, generating manufacturing defects
Solution Approach 1:
The invention divides the peripheral area into multiple support regions with openings, creating a segmented supporting layer that provides localized support to prevent sagging while maintaining the overall thin and flexible structure of the plastic substrate
Solution Approach 2:
The supporting layer is configured with different properties in different regions: it provides mechanical support in the peripheral area where sagging occurs, while maintaining transparency and flexibility in the display area, achieving local optimization of structural properties
2Stability of the object's composition
If a relatively thicker plastic film is used to control the sagging of the plastic film, then the sagging is reduced, but the cost for manufacturing increases
Solution Approach 1:
The supporting layer is segmented with openings that allow sealant to penetrate and provide reinforcement at critical points, enabling the use of thinner plastic film while maintaining stability through the combined structure of plastic film plus sealant in the peripheral region
Solution Approach 2:
The invention creates a composite structure by combining the plastic substrate with a supporting layer and sealant material in the peripheral area, where the sealant fills the openings and bonds to both the substrate and supporting layer, providing enhanced mechanical strength and sagging prevention without increasing plastic film thickness
3Productivity
If the plastic film is stripped off from the carrier substrate, then the TFT manufacturing process is completed, but the plastic film sags due to its thin thickness, generating various defects
Solution Approach 1:
The supporting layer with openings is configured in advance on the plastic substrate before the TFT manufacturing process is completed. This preliminary structure is designed to prevent sagging that would occur after stripping from the carrier substrate, ensuring substrate flatness is maintained throughout the manufacturing process and during final assembly
Solution Approach 2:
The supporting layer acts as an intermediary structure between the thin plastic substrate and the external environment, providing mechanical support and preventing sagging without interfering with the TFT manufacturing process or the final display functionality
Data Source
AI summary
A display panel includes a substrate, an electro-optical layer and a supporting layer. The substrate includes a display area and a peripheral area surrounding the display area. A thin-film transistor (TFT) part is formed in the display area. The electro-optical layer is disposed in the display area of the substrate. The supporting layer is disposed on the electro-optical layer and faces both the display area and the peripheral area, openings being formed through the supporting layer in the peripheral area. Accordingly, the supporting layer may prevent the substrate from sagging and may protect the gate circuit part.