Flexible Display Substrate Vacuum Bonding via Sealed Frame
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Solution Overview
Problem
The existing manufacturing methods for flexible OLED panels face issues with damage to components during the stripping process of the plastic substrate from the glass substrate, as the plastic substrate can deform and cause films and components to be damaged.
Innovation Solution
A method involving a rigid glass substrate with etched glass supporting pillars and a sealed plastic frame, where the flexible substrate is bonded to the rigid substrate within a vacuum environment, and then separated by cutting along the internal side of the sealed plastic frame, eliminating the need for manual stripping and reducing component damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plastic substrate is stripped manually from the glass substrate, then the flexible OLED panels can be obtained, but the plastic substrate may bend and cause films and components to be damaged
Solution Approach 1:
The patent introduces a sealed frame structure that divides the substrate into a working area and a non-working area. The flexible substrate is fixed to the glass substrate within the sealed frame through vacuum adhesion, while the non-working area allows for clean separation. This segmentation enables damage-free removal of the flexible substrate without manual stripping.
Solution Approach 2:
The patent uses vacuum adhesion as an intermediary mechanism to temporarily bond the flexible substrate to the glass substrate during manufacturing. This vacuum-based bonding allows for secure fixation during component formation, then enables clean separation when needed, replacing the harmful manual stripping process.
2Adaptability or versatility
If the plastic substrate is used as flexible substrate, then the display can be made flexible, but the substrate cannot be manufactured alone and requires adhesion to glass substrate
Solution Approach 1:
The patent divides the substrate system into distinct functional zones: a flexible working area for display components and a rigid non-working area with the sealed frame for structural support and vacuum adhesion. This segmentation allows the flexible substrate to maintain its flexibility where needed while providing structural stability where required.
Solution Approach 2:
The patent applies different properties to different regions of the substrate system. The flexible substrate maintains its flexibility in the working area while being locally reinforced and secured in the non-working area through vacuum adhesion to the rigid glass substrate, creating local structural integrity without compromising overall flexibility.
3Reliability
If vacuum adhesion is used to bond flexible substrate to rigid substrate, then secure fixation is achieved, but the sealed plastic frame must be formed first
Solution Approach 1:
The patent performs preliminary actions by forming the sealed frame structure and establishing vacuum adhesion before depositing any display components on the flexible substrate. This preliminary fixation ensures the substrate remains stable and properly positioned throughout the subsequent manufacturing processes, preventing misalignment or movement.
Solution Approach 2:
The patent combines multiple functions into the sealed frame structure: it serves as a boundary marker, a vacuum seal, and a structural support element. By merging these functions into a single integrated component, the patent reduces the number of separate manufacturing steps needed while maintaining strong adhesion and proper substrate positioning.
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 method effectively prevents component malfunction by ensuring secure adhesion and separation of the flexible substrate from the rigid substrate, maintaining the integrity of the components throughout the manufacturing process.
Implementation Method 1
within a vacuum environment, bonding the rigid substrate with the flexible substrate
Implementation Method 2
after the rigid substrate and the flexible substrate are taken out from the vacuum environment, an area of the flexible substrate within the sealed plastic frame is adhered to the rigid substrate due to negative pressure
Data Source
AI summary
A manufacturing method of flexible display panels and the substrate components thereof are disclosed. The method includes: providing a rigid substrate and a flexible substrate; forming a sealed plastic frame on the rigid substrate and/or flexible substrate; within a vacuum environment, bonding the rigid substrate with the flexible substrate and curing the sealed plastic frame to fix the flexible substrate on the rigid substrate, after taken out from the vacuum environment, an area of the flexible substrate within the sealed plastic frame is adhered to the rigid substrate due to negative pressure; forming at least one display component on the flexible substrate; and cutting the rigid substrate and/or the flexible substrate to separate the flexible substrate and the rigid substrate. In this way, the components are prevented from being failed when the flexible substrate is stripped during the manufacturing process of the flexible substrate.