Flexible OLED Substrate with Polysilicon Protrusions for Rift Prevention
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Solution Overview
Problem
Existing organic light emitting diode (OLED) displays with flexible substrates face challenges in maintaining structural integrity and preventing rifts when repeatedly bent, affecting the quality and reliability of the display.
Innovation Solution
A flexible substrate is manufactured with a polysilicon layer having irregularly or regularly arranged protrusions, and a second flexible layer is formed on top, using a method that includes crystallization by excimer laser annealing or sequential lateral solidification, with a barrier layer to enhance moisture prevention and surface roughness, ensuring the substrate's durability and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a flexible substrate is used in OLED displays, then thickness and weight are reduced, but structural integrity and resistance to rifts during repeated bending deteriorate
Solution Approach 1:
The patent employs a composite flexible substrate structure consisting of multiple layers including a base flexible layer, a polysilicon layer with protrusions, and a second flexible layer. This multi-layer composite construction enhances structural integrity and resistance to rifts during repeated bending while maintaining the overall flexibility and reduced weight of the display device.
2Object-affected harmful factors
If a polysilicon layer with protrusions is formed, then surface roughness and moisture prevention are enhanced, but manufacturing complexity increases
Solution Approach 1:
The protrusions are formed on the polysilicon layer during the crystallization process itself, rather than requiring a separate post-processing step. The excimer laser annealing or sequential lateral solidification method inherently creates the protrusion structure as the amorphous silicon crystallizes, thereby preventing moisture penetration while avoiding additional manufacturing complexity.
3Reliability
If excimer laser annealing or sequential lateral solidification is used for crystallization, then protrusions are formed to prevent rifts, but manufacturing time and energy consumption increase
Solution Approach 1:
The patent utilizes phase transition of silicon from amorphous to crystalline state through excimer laser annealing or sequential lateral solidification. This phase transition process inherently forms protrusions on the polysilicon layer surface that prevent rift formation during bending. The method achieves both rift prevention and protrusion formation in a single crystallization step, optimizing manufacturing efficiency.
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 solution provides a high-quality OLED display that maintains structural integrity and prevents rifts even with repeated bending, ensuring a reliable and high-performance flexible OLED display.
Implementation Method 1
The crystallization may be performed by an excimer laser annealing method
Implementation Method 2
The crystallization may be performed by an excimer laser annealing method
Implementation Method 3
The crystallization may be performed by the sequential lateral solidification method
Implementation Method 4
an organic light emitting diode emitting light
Data Source
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AI summary
A flexible substrate (100), a method of manufacturing the same, and an organic light emitting diode display, the flexible substrate (100) including a first flexible layer (10); a polysilicon layer (20) on the first flexible layer, the polysilicon layer (20) having a plurality of protrusions (7) on a surface thereof; and a second flexible layer (30) on the polysilicon layer.