Flexible Display Substrate Manufacturing via Backing Layer Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current flexible display manufacturing methods face issues with plastic deformation and unevenness of the flexible base substrate due to the irregular surface of rigid glass substrates, leading to quality defects in the display substrate.
Innovation Solution
A manufacturing method involving a backing layer on a carrier substrate, where a flexible base substrate is prepared on the backing layer and then the backing layer is removed, ensuring precise positioning and flatness without contact with the carrier substrate, thereby avoiding plastic deformation and ensuring the quality of the flexible display substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flexible base substrate is directly placed on a rigid glass seat for manufacturing, then the substrate can be fixed and processed, but the undulation of the glass surface causes bubbles and plastic deformation of the flexible substrate
Solution Approach 1:
A flat rigid support substrate is introduced as an intermediary between the flexible base substrate and the undulated glass seat. The flexible substrate is bonded to this flat support substrate, which provides a smooth, flat surface that prevents bubble formation and plastic deformation during manufacturing, while still allowing the flexible substrate to be properly positioned and processed
Solution Approach 2:
The manufacturing process is segmented into distinct stages: first bonding the flexible substrate to the flat rigid support substrate, then performing electronic element fabrication, and finally separating the flexible substrate from the support substrate. This segmentation allows the flat support substrate to serve its protective function only during the critical manufacturing phase
2Strength
If a rigid glass seat with undulation is used as the manufacturing base, then the structural strength is sufficient, but the surface flatness is inadequate causing quality issues
Solution Approach 1:
The flat rigid support substrate acts as a mediator that decouples the strength function from the flatness function. The glass seat provides structural strength, the flat rigid support substrate provides surface flatness, and together they enable both strong support and precise manufacturing without requiring the glass seat itself to be perfectly flat
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
This method effectively prevents plastic deformation and ensures the quality of the flexible display substrate by isolating the flexible base substrate from the carrier substrate, maintaining precise positioning and flatness, thus enhancing the manufacturing process.
Implementation Method 1
using UV-degradable materials and photolysis to avoid deformation
Data Source
AI summary
An embodiment of the invention provides a manufacturing method of flexible display substrate (10) comprising: preparing a backing layer (2) on a carrier substrate (1); preparing a flexible base substrate (3) on the backing layer (2); preparing electronic components (4) on the flexible base substrate (3); and removing the backing layer (2) from the flexible base substrate (3) back to obtain a flexible display substrate (10).