Flexible Glass Multilayer Structure via Phase Separation
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Solution Overview
Problem
Existing flexible glass substrates lack sufficient flexibility, durability, and shatter resistance, and the manufacturing processes are complex and costly, making them unsuitable for thin, lightweight, and foldable display devices.
Innovation Solution
A flexible glass substrate multilayer structure is developed using phase separation to form a shatter-proof layer and a hard coating layer in a single coating process, enhancing adhesion and reducing thickness and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flexible glass substrate is made thinner to achieve flexibility, then flexibility is improved, but durability and shatter resistance deteriorate
Solution Approach 1:
The patent applies composite materials by forming a multilayer functional coating on the flexible glass substrate that combines a shatter-proof layer and a hard coating layer. This composite structure provides both flexibility (through the thin glass substrate) and durability (through the combined functional layers), resolving the contradiction between thinness/flexibility and shatter resistance.
Solution Approach 2:
The patent segments the functional coating into distinct layers with specific functions: a shatter-proof layer for impact resistance and a hard coating layer for surface hardness. This segmentation allows each layer to optimize its specific function while working together to provide overall durability, solving the contradiction between flexibility and shatter resistance.
2Reliability
If functional layers are laminated using conventional methods with adhesive, then adhesion is improved, but overall thickness and weight increase
Solution Approach 1:
The patent merges multiple functional layers (shatter-proof layer and hard coating layer) into a single integrated coating formed by phase separation from a unified composition. This eliminates the need for separate adhesive layers and multiple lamination steps, thereby improving adhesion while reducing overall thickness and weight compared to conventional laminated structures.
Solution Approach 2:
The patent uses phase separation as an intermediary mechanism to create distinct functional layers from a single homogeneous coating composition. During the drying or curing process, the composition spontaneously separates into regions with different properties, forming the shatter-proof and hard coating layers without requiring external adhesives, thus reducing thickness while maintaining adhesion.
3Reliability
If multiple functional layers are formed by separate coating processes, then functional properties are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple coating processes into a single coating step by formulating a unified composition that contains all necessary components for both the shatter-proof layer and the hard coating layer. The phase separation during drying or curing automatically creates the distinct functional layers, significantly simplifying the manufacturing process while maintaining excellent functional properties.
Solution Approach 2:
The patent creates a universal coating composition that performs multiple functions: it forms both the shatter-proof layer and the hard coating layer through phase separation, provides adhesion to the glass substrate, and delivers all required functional properties. This multi-functional approach eliminates the need for separate coating processes and reduces manufacturing complexity.
4Ease of manufacture
If a single coating forms both shatter-proof and hard coating functions, then manufacturing simplicity is improved, but adhesion and layer differentiation may deteriorate
Solution Approach 1:
The patent uses phase separation as an intermediary process that occurs during drying or curing to differentiate the layers within the single coating. This spontaneous separation mechanism ensures proper layer differentiation and adhesion without requiring complex manufacturing steps, thereby maintaining both manufacturing simplicity and functional reliability.
Solution Approach 2:
The patent controls the phase separation process by adjusting parameters such as composition ratios, drying conditions, and curing parameters. These parameter changes ensure that the single coating properly differentiates into distinct shatter-proof and hard coating layers with excellent adhesion, resolving the potential deterioration of layer differentiation while maintaining manufacturing simplicity.
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 resulting flexible glass substrate multilayer structure exhibits excellent flexibility, shatter resistance, impact resistance, and optical properties, suitable for use in flexible display panels, while simplifying the production process and reducing costs.
Implementation Method 1
the functional layer is phase-separated in a drying or curing process after a single coating and formed into two or more layers
Data Source
AI summary
Provided are a glass multilayer structure, a method of producing the same, and a flexible display panel including the same. More particularly, a glass substrate multilayer structure including a flexible glass substrate; and a functional layer formed on at least one surface of the flexible glass substrate. The functional layer is a phase-separated layer formed by a single coating and a flexible display panel including the same are provided.