Flexible Substrate Island-Strip Segmentation for Crack Prevention

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Solution Overview

Problem

Flexible substrates with electrical elements face challenges in preventing wiring damage due to stress caused by bending and stretching, and existing technologies do not effectively address the issue of crack propagation and moisture penetration in flexible electronic devices.

Innovation Solution

The electronic device incorporates a flexible substrate with an insulating base, organic and inorganic insulating films, wirings, electrical elements, a barrier wall, and a sealing film. The barrier wall, composed of a metal first layer and an inorganic insulating second layer, separates the electrical elements from the organic layer and upper electrode, preventing crack propagation and moisture penetration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a flexible substrate with electrical elements is used, then flexibility and elasticity are achieved, but wirings are damaged by stress caused by bending and stretching

Engineering Contradiction:

ImproveflexibilityVSAvoidwiring integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The substrate is divided into island-shaped portions and strip-shaped portions, where the strip-shaped portions provide flexibility through elastic deformation while the island-shaped portions contain the electrical elements. This segmentation allows the flexible substrate to bend and stretch without damaging the wirings connecting the electrical elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a flexible substrate structure that can elastically deform under stress. The substrate includes multiple layers (insulating base, organic insulating film, inorganic insulating film, sealing film) that maintain flexibility while protecting the electrical elements and wirings during bending and stretching operations.

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If electrical elements are disposed on a flexible substrate, then the device can be attached to curved surfaces, but cracks propagate and moisture penetrates under stress

Engineering Contradiction:

Improvecurved surface attachmentVSAvoidcrack propagation and moisture penetration

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

By dividing the substrate into island-shaped portions (containing electrical elements) and strip-shaped portions (提供 flexibility), the patent prevents crack propagation from affecting the electrical elements during bending. The strip-shaped portions act as flexible connectors that can deform without transmitting stress to the island-shaped portions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs multiple protective layers (organic insulating film, inorganic insulating film, sealing film) that are disposed before the device is subjected to stress. These layers provide pre-established protection against crack propagation and moisture penetration, cushioning the electrical elements from harmful effects before they occur.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 3:

The multi-layer flexible substrate structure includes sealing films and insulating films that conform to curved surfaces while maintaining their protective function. These thin films provide barrier protection against moisture and crack propagation even when the device is bent or stretched on curved surfaces.

Inventive Principle:

Principle #30Flexible shells and thin films

3Manufacturing precision

If a pixel division structure is used to divide organic layer and cathode, then electrical element separation is achieved, but protection against stress and moisture is insufficient

Engineering Contradiction:

Improveelement separationVSAvoidstress and moisture resistance

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The pixel division structure divides the substrate into island-shaped portions containing electrical elements and strip-shaped portions providing structural support and flexibility. This segmentation achieves both precise element separation and enhanced protection against stress and moisture through the multi-layer configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a composite multi-layer structure including insulating base, organic insulating film, inorganic insulating film, and sealing film. This composite structure provides both the element separation needed for pixel division and the enhanced protection against stress and moisture penetration required for reliable flexible electronics.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12328994B2Electronic device

Publication Date: 2025.06.10 MAGNOLIA WHITE CORP

AI summary

An electronic device includes an insulating base including a strip-shaped portion having elasticity and an island-shaped portion connected to the strip-shaped portion, an organic insulating film disposed on the insulating base, an inorganic insulating film disposed on the organic insulating film, a wiring disposed between the strip-shaped portion and the organic insulating film, an electrical element disposed on the inorganic insulating film and electrically connected to the wiring, in the island-shaped portion, a barrier wall overlapping the island-shaped portion and the strip-shaped portion and surrounding the electrical element, and a sealing film covering the electrical element.