Flexible Substrate Segmented Planarization for Barrier Integrity

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Flexible polymer substrates used in organic optoelectronic devices are prone to water and oxygen infiltration, leading to device failure, and existing solutions require multiple layers and precise masking for different sizes, increasing production costs and limiting scalability.

Innovation Solution

A flexible substrate design featuring a polymer substrate with periodically arranged planarization units and water and oxygen barrier layers, where the planarization units are separated in multiple directions, allowing the barrier layers to cover gaps and overlap, enabling the substrate to be cut to any size while maintaining barrier effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple water and oxygen barrier layers are provided on the polymeric substrate, then the water and oxygen barrier capacity is improved, but the device complexity and production cost increase due to requiring precise masking for different sizes

Engineering Contradiction:

Improvewater and oxygen barrier capacityVSAvoidproduction process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The planarization layer is segmented into periodically arranged planarization units separated in multiple directions, creating a modular structure that simplifies the overall manufacturing process while maintaining barrier effectiveness

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The planarization units serve multiple functions: they provide planarization for film formation, create gaps for barrier layer coverage, and enable the substrate to be cut to any size while maintaining barrier effectiveness, eliminating the need for size-specific masking

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If the substrate is cut to different sizes to meet product requirements, then the adaptability is improved, but the water and oxygen barrier capacity deteriorates because the side surface after cutting is exposed to external air

Engineering Contradiction:

Improvesubstrate size adaptabilityVSAvoidwater and oxygen barrier capacity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The barrier layers are positioned to cover the gaps between planarization units at the cut edges, providing localized protection where it is most needed - at the exposed side surfaces - while the rest of the structure maintains its planarization function

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The planarization units are separated in multiple directions (first and second directions), creating a three-dimensional protective structure where barrier layers can cover gaps from multiple angles, effectively sealing the cut surfaces

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Productivity

If roll-to-roll coating is used for large-scale production, then the productivity is improved, but the manufacturing precision deteriorates because the existing masking method is unsuitable for roll-to-roll processing

Engineering Contradiction:

Improveproduction capacityVSAvoidbarrier layer coverage precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The planarization units are pre-arranged in a periodic pattern with gaps positioned to align with barrier layers, so that when the substrate is cut and processed via roll-to-roll coating, the barrier layers automatically cover the critical gap areas without requiring complex masking

Inventive Principle:

Principle #10Preliminary action

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 design enhances the water and oxygen barrier capabilities, reduces production costs, and allows for large-scale production of flexible substrates suitable for various sizes, simplifying the manufacturing process and extending device lifespan.

Implementation Method 1

The water permeation rate and oxygen permeation rate of common polymer substrates are shown in the table below

Methodology Applied

Scientific EffectPermeation barrier: Permeation

Implementation Method 2

a planarization layer 102 is provided between the adjacent water and oxygen barrier layers 103 in order to guarantee the compactness and smoothness of the film formation and inhibit the growth of the defect in the film

Methodology Applied

Scientific EffectPlanarization:

Data Source

PatentUS10109809B2Flexible substrate

Publication Date: 2018.10.23 KUNSHAN NEW FLAT PANEL DISPLAY TECHNOLOGY CENTER CO LTD

AI summary

A flexible substrate includes a polymer substrate and a plurality of water and oxygen barrier layers provided on the polymer substrate. A planarization layer is provided between the adjacent water and oxygen barrier layers. The planarization layer includes a plurality of planarization units separated in a first direction and a second direction. A projection of the planarization unit in the planarization layer projected on the polymer substrate covers a gap between projections of adjacent planarization units in an adjacent planarization layer projected on the polymer substrate, and projection regions partially overlap. The adjacent planarization layers can cover the gap between the planarization units to prevent the water and oxygen horizontal from penetrating to ensure that the flexible substrate can be cut into any size within the range lager than the size of the planarization unit.