Flexible Substrate Coating with Overlapping Film Layers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In flexible substrate manufacturing, the formation of unstable thickness regions at the periphery of coated film layers due to surface tension and liquid flow leads to reduced coating area and increased thickness irregularities with multiple layers.
Innovation Solution
A method involving coating a glass carrier with a first film layer, followed by a second film layer with a greater area, which covers the unstable regions, and peeling off the layers to form a flexible substrate, optionally using a blocking layer and slit extrusion coating to achieve planarization and increase the usable coating area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple film layers are coated on the glass carrier, then the thickness of the flexible substrate is increased, but the unstable thickness region at the periphery becomes larger and more severe
Solution Approach 1:
The coating process is segmented into multiple sequential coating operations, where each layer is coated separately with controlled parameters. The second film layer is specifically designed to cover the unstable thickness region of the first layer, dividing the coating process into distinct stages that address different functional requirements.
Solution Approach 2:
The first film layer is coated as a preliminary layer that intentionally allows for an unstable thickness region at its periphery. This preliminary action sets up the condition for the second coating operation, where the second film layer is specifically applied to cover and compensate for the unstable region of the first layer.
2Quantity of substance
If the film layer thickness is increased to meet substrate requirements, then the flexible substrate performance is improved, but the raised region at the periphery becomes more pronounced
Solution Approach 1:
The solution moves from a single-layer thickness control approach to a multi-layer approach, where the second film layer is applied with a larger area than the first layer. This dimensional change in the coating area allows the second layer to cover the raised region of the first layer, compensating for surface flatness issues while maintaining the required total thickness.
Solution Approach 2:
Different regions of the film structure are given different qualities: the first film layer provides the base thickness, while the second film layer is specifically designed with a larger area to cover and planarize the unstable thickness region at the periphery of the first layer, creating local quality differentiation.
3Ease of manufacture
If conventional coating methods are used, then the coating process is simple, but the applicable process area is reduced due to the unstable thickness region
Solution Approach 1:
The coating process is made dynamic by adjusting the coating area for different layers. The second film layer is coated with a larger area than the first layer, allowing the process to adapt to and cover the unstable thickness region, thereby increasing the usable coating area while maintaining process 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
This method effectively reduces unstable thickness regions, increases the applicable process area, and eliminates the issues of small coating areas and large irregularities by covering the unstable edges with the second film layer, resulting in a more stable and efficient flexible substrate production.
Implementation Method 1
a raised region, where a thickness of the film layer is unstable, is formed at a periphery of the coated film layer, due to surface tension of the material
Implementation Method 2
a raised region, where a thickness of the film layer is unstable, is formed at a periphery of the coated film layer, due to surface tension of the material, or a combined effect of surface tension and liquid flow
Data Source
AI summary
A method for manufacturing a flexible substrate, a flexible substrate manufactured using the method and a display device including the flexible substrate are disclosed. The method includes steps of: coating a glass carrier with a plurality of film layers, wherein each of at least one pair of adjacent film layers of the plurality of film layers is formed through steps of: S1: coating the glass carrier with a first film layer; and S2: coating the glass carrier with a second film layer over the first film layer so that the second film layer covers the first film layer, wherein the second film layer has an area greater than an area of the first film layer; and peeling off the plurality of formed film layers from the glass carrier to form a flexible substrate.