Flexible Device Substrate With Oxide-Glass Adhesion Structure
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Solution Overview
Problem
Substrates for flexible devices, such as organic EL lighting and solar cells, face challenges with moisture barrier properties, adhesion, bending strength, and manufacturing complexity, particularly with stainless steel sheets where nickel plating is required for adequate adhesion and rust resistance.
Innovation Solution
A substrate comprising a stainless steel sheet with a chromium-rich oxide layer and a bismuth-based glass layer, where the oxide layer thickness and chromium concentration enhance adhesion and bending strength, eliminating the need for nickel plating and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stainless steel sheet is used as the metal sheet, then rust resistance is improved, but adhesion between the metal sheet and glass layer deteriorates
Solution Approach 1:
A nickel plating layer is introduced as an intermediary between the stainless steel sheet and the glass layer. The nickel plating layer provides excellent adhesion to both the stainless steel substrate and the glass coating, solving the adhesion problem while maintaining the rust resistance of the stainless steel base material.
Solution Approach 2:
The substrate structure is designed as a composite material system consisting of multiple layers: stainless steel sheet, nickel plating layer, and glass layer. Each layer contributes specific properties - the stainless steel provides rust resistance, the nickel plating provides adhesion, and the glass provides insulation and smoothness, achieving overall performance optimization.
2Strength
If a nickel plating layer is formed on the stainless steel sheet, then adhesion is improved, but manufacturing complexity increases
Solution Approach 1:
The invention optimizes specific parameters of the nickel plating layer, including thickness (5-50 nm) and chromium concentration at the interface (30-80 atomic %), to achieve sufficient adhesion with minimized plating thickness, thereby reducing manufacturing complexity and cost while maintaining performance.
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 substrate achieves excellent moisture barrier, adhesion, and bending strength, reducing manufacturing steps and improving quality control, while preventing rust and peeling, making it suitable for flexible device applications like organic EL lighting and solar cells.
Implementation Method 1
a chromium-rich oxide layer... where the oxide layer thickness and chromium concentration enhance adhesion
Implementation Method 2
a glass layer of electrically-insulating bismuth-based glass in a form of layer formed on the surface of the oxide layer
Data Source
AI summary
A substrate for flexible device, including a stainless steel sheet, an oxide layer formed on a surface of the stainless steel sheet, and a glass layer of electrically-insulating bismuth-based glass formed in a form of layer on the surface of the oxide layer. Also disclosed is a sheet for flexible device, including a stainless steel sheet, and an oxide layer on a surface of the stainless steel sheet, the oxide layer having a thickness of not less than 30 nm.