Flexible Pixel Array Substrate Release Layer Separation
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Solution Overview
Problem
The challenge in fabricating flexible pixel array substrates is efficiently separating the plastic substrate from the glass substrate during the sheet-to-sheet process, and the plastic substrates lack sufficient water vapor and oxygen resistance, limiting their application and lifespan.
Innovation Solution
A method involving the formation of a release layer with higher adhesive strength to the rigid substrate than to the polymer film, allowing easy separation, and incorporating a water vapor-resistant and oxygen-resistant film layer on the flexible substrate to enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a plastic substrate is used for flexible FPD fabrication, then flexibility and thinness are improved, but separation from the glass substrate becomes difficult
Solution Approach 1:
A release layer is introduced as an intermediary between the plastic substrate and glass substrate. This release layer has controlled adhesive properties that allow easy separation after the pixel structures are formed, solving the separation difficulty while maintaining the flexibility benefits of the plastic substrate
Solution Approach 2:
The substrate structure is segmented into multiple functional layers: the glass substrate, the release layer, and the plastic substrate with pixel structures. This segmentation allows each layer to perform its specific function independently, with the release layer facilitating easy separation
2Adaptability or versatility
If the plastic substrate is made softer for flexibility, then adaptability is improved, but control during fabrication becomes harder
Solution Approach 1:
The plastic substrate is affixed to the rigid glass substrate before fabrication begins. This preliminary action provides mechanical support and stability during the fabrication process, making the soft plastic substrate easier to control, while still achieving the desired flexibility in the final flexible FPD product
3Shape
If the plastic substrate material is used currently, then flexibility is improved, but resistance to water vapor and oxygen is insufficient
Solution Approach 1:
The plastic substrate is combined with protective film layers that provide resistance to water vapor and oxygen. This composite structure maintains the flexibility of the plastic substrate while adding the necessary protection against environmental factors, thereby improving reliability and lifespan
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
Enables quick and efficient separation of the polymer film from the rigid substrate and improves the substrate's resistance to water vapor and oxygen, expanding its application scope and extending its lifespan.
Implementation Method 1
the adhesive strength between the rigid substrate and the release layer is higher than that between the release layer and the polymer film
Implementation Method 2
the formation of the polymer film includes spin coating a polymer monomer and performing a curing process to form a polymer layer
Implementation Method 3
the formation of the polymer film includes spin coating a polymer monomer
Implementation Method 4
the above-mentioned film layer includes a water vapor-resistant and oxygen-resistant layer, which is made of oxide, nitride, polymer or a multi-layer combination of the above materials
Data Source
AI summary
The present invention provides a method for fabricating a flexible pixel array substrate as follows. First, a release layer is formed on a rigid substrate. Next, on the release layer, a polymer film is formed, the adhesive strength between the rigid substrate and the release layer being higher than that between the release layer and the polymer film. The polymer film is formed by spin coating a polymer monomer and performing a curing process to form a polymer layer. Afterwards, a pixel array is formed on the polymer film. The polymer film with the pixel array formed thereon is separated from the rigid substrate.