Flexible Substrate With Transparent Textile and Low-Contraction Planarization
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Solution Overview
Problem
The challenge lies in manufacturing flexible display devices that can replace glass substrates with plastic substrates, requiring flexible substrates that maintain structural stability and optical characteristics while being capable of being folded or rolled, which existing technologies have difficulty in achieving.
Innovation Solution
A flexible substrate is created using a transparent textile with intersecting fibers coated with a resin layer, and a planarization layer is formed using an organic material with a curable contraction rate of no greater than 20%, which is then cured and planarized using a supporting substrate or mold to achieve a flatness of less than 100 nm, addressing the need for flexibility and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a glass substrate is replaced with a plastic substrate to achieve flexibility, then the substrate can be folded or rolled, but the structural stability and manufacturing difficulty deteriorate
Solution Approach 1:
The patent uses a composite structure consisting of a plastic substrate combined with a resin layer and an organic material layer. This composite material approach allows the substrate to maintain flexibility from the plastic base while gaining structural stability through the additional layers, resolving the contradiction between flexibility and structural integrity
Solution Approach 2:
The patent specifies that the organic material must have a curable contraction rate of no greater than 20%. By controlling this physical parameter of the organic material, the substrate achieves both flexibility (from the plastic base) and structural stability (through controlled curing contraction), preventing excessive deformation during the curing process
2Adaptability or versatility
If a plastic substrate is used instead of glass, then flexibility is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent applies a planarization layer on the plastic substrate before subsequent manufacturing steps. This preliminary action ensures that the substrate surface achieves the required flatness (equal to or less than 100 nm) before other components are added, maintaining manufacturing precision while preserving the underlying flexibility of the plastic substrate
Solution Approach 2:
The patent controls the curable contraction rate of the organic material to be no greater than 20%. This parameter control prevents excessive shrinkage during curing, ensuring that the substrate maintains its flatness and dimensional accuracy throughout the manufacturing process while remaining flexible
3Manufacturing precision
If an organic material layer is added for planarization, then flatness is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent specifies that the organic material must have a curable contraction rate of no greater than 20%. This single parameter control achieves two objectives: it ensures the organic material layer planarizes the substrate surface effectively while preventing excessive contraction that would complicate the manufacturing process. The controlled contraction rate allows for predictable and manageable curing behavior
Solution Approach 2:
The patent applies the organic material layer specifically where planarization is needed, with the layer's thickness and properties optimized for the local requirements of the substrate surface. This localized approach achieves the necessary flatness without unnecessarily complicating the overall manufacturing process
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 resulting flexible substrate exhibits enhanced mechanical stability and optical characteristics, enabling the production of flexible display devices that can be folded or rolled without compromising their structural integrity or display quality.
Implementation Method 1
coating an organic material on the flexible mother substrate, curing the organic material to form an organic material layer on the flexible mother substrate
Implementation Method 2
an organic material having a curable contraction rate of no greater than about 20%
Implementation Method 3
the resin layer coats the transparent textile to fill a space between the first and second transparent fibers
Implementation Method 4
coating the transparent textile with a resin layer such that the resin layer fills a space between the first and second transparent fibers
Implementation Method 5
planarizing the organic material layer by pressuring the organic material layer with a second supporting substrate opposite to the first supporting substrate
Data Source
AI summary
A flexible substrate includes a flexible mother substrate and a planarization layer on the flexible mother substrate. Here, the flexible mother substrate includes a transparent textile and a resin layer. The transparent textile includes a plurality of first transparent fibers and a plurality of second transparent fibers crossing the plurality of first transparent fibers, and the resin layer coats the transparent textile to fill a space between the first and second transparent fibers. The planarization layer includes an organic material having a curable contraction rate of no greater than about 20%.