Flexible Substrate Patterning with Tension Correction Units

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Solution Overview

Problem

Flexible substrates used in display devices are difficult to align and pattern due to their flexible nature, making it challenging to form precise patterns and correct distortions, which is exacerbated by their inability to be easily bent or protected.

Innovation Solution

A patterning apparatus with a stage and correction units that apply tension forces to the flexible substrate, combined with a pattern forming unit, to correct distortions and maintain a flat surface for precise pattern formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a flexible substrate is used to enable bending and portability, then flexibility and durability are improved, but alignment precision and pattern formation accuracy deteriorate

Engineering Contradiction:

ImproveflexibilityVSAvoidalignment precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The correction units apply tension forces to the flexible substrate before the patterning process to pre-correct distortions and maintain a flat surface, ensuring that the substrate is in the optimal state for precise pattern formation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The correction units dynamically adjust the tension force parameters applied to different regions of the flexible substrate to correct distortions and maintain flatness during the patterning process

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If tension force is applied to correct substrate distortion, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improvepattern formation accuracyVSAvoidapparatus complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The correction system is divided into multiple independent correction units that can be distributed along the substrate processing path, allowing for localized distortion correction without requiring a completely complex centralized system

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The correction units are designed to perform multiple functions: applying tension force, correcting distortions, and maintaining substrate flatness, thereby reducing the need for separate dedicated devices for each function

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 apparatus effectively corrects distortions and allows for precise pattern formation on flexible substrates, improving the adaptability and durability of flexible display devices by maintaining a flat surface and reducing misalignment.

Implementation Method 1

a plurality of correction units being adjacent to the stage, attached to the flexible substrate, and applying a tension force to the flexible substrate

Methodology Applied

Scientific EffectTension force: Tension

Data Source

PatentUS8985994B2Patterning apparatus

Publication Date: 2015.03.24 LG DISPLAY CO LTD

AI summary

A patterning apparatus includes a stage arranged under a flexible substrate, a plurality of correction units arranged closely to the stage, attached to the flexible substrate, and configured to apply a tension force to the flexible substrate, and a pattern forming unit configured to form a pattern on the flexible substrate. The patterning apparatus corrects distortion of the flexible substrate by using the correction units.