Flexible Display Thermal Isolation Layer Design
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Solution Overview
Problem
Conventional flexible OLED display manufacturing processes using soft glass plates face issues with increased brittleness and cracking due to high temperature and laser-based separation methods, leading to performance degradation and reduced product yield.
Innovation Solution
A method involving a connection layer deposited by PECVD, a flexible base plate with a soft glass plate and thermal isolation layers on one or both sides, and a blocking layer to enhance bonding and isolate heat during high temperature processes, allowing for effective separation without cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high temperature process and laser based separation are applied to separate the flexible display device from the carrier plate, then the separation efficiency is improved, but the brittleness of the soft glass plate increases causing cracking
Solution Approach 1:
A release layer is introduced as an intermediary between the soft glass plate and the carrier plate. This release layer absorbs the thermal impact during high temperature processes and laser separation, preventing direct thermal damage to the soft glass plate while enabling efficient separation. The release layer acts as a buffer that protects the fragile soft glass from the harsh separation conditions.
2Ease of manufacture
If conventional release layers and bonding layers are used in the manufacturing process, then the separation process is simplified, but the bonding strength between the flexible base plate and carrier plate is insufficient
Solution Approach 1:
The release layer is constructed as a composite structure with multiple functional layers including a bonding layer and a release layer. The bonding layer provides strong adhesion to both the carrier plate and the soft glass plate, while the release layer provides controlled release capability. This composite structure simultaneously achieves strong bonding and easy separation.
3Strength
If thin stainless steel plates are used as the base plate, then the structural strength is improved, but the surface roughness increases requiring additional planarization layers
Solution Approach 1:
The base plate is constructed as a composite structure combining a thin stainless steel substrate with a soft glass plate layer. The thin stainless steel provides structural strength and flexibility, while the soft glass plate provides a smooth surface for device fabrication. This composite approach achieves both structural integrity and surface quality without requiring additional planarization layers.
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 method prevents brittleness and cracking in soft glass plates, enhancing the performance and yield of flexible OLED displays by reducing thermal impact and improving bonding strength between the flexible base plate and carrier board.
Implementation Method 1
depositing a connection layer on the carrier board by plasma enhanced chemical vapor deposition (PECVD)
Implementation Method 2
applying a laser based process to separate the carrier board and the flexible base plate
Data Source
AI summary
The present invention provides a method for manufacturing a flexible display device and a flexible display device so manufactured. The method for manufacturing a flexible display device according to the present invention uses a connection layer to replace a release layer and a bonding layer that are commonly used in the prior art so as to enhance the bonding strength between a flexible backing plate and a rigid carrier board and to additionally function as a release layer for easily achieving separation between the flexible backing plate and the rigid carrier board; and further, a thermal isolation layer is provided on one side or two sides of the soft glass plate to isolate heat generated in a high temperature process, an ELA process, or a laser based separation process and thus reduce thermal impact caused the heat on the soft glass plate and the display device so as to prevent cracking resulting from increase of brittleness of the soft glass plate and enhance performance of a flexible display device.