Gradient Gas Barrier Layer for Flexible Displays
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Solution Overview
Problem
Existing flexible display substrates using transparent plastic films face challenges with gas barrier capabilities, as metal oxide layers can crack when bent, leading to reduced performance and increased production complexity and costs.
Innovation Solution
A formed article with a gas barrier layer composed of a material containing oxygen, carbon, and silicon atoms, where the oxygen content decreases and carbon content increases in depth, achieved by ion implantation into a polyorganosiloxane compound-containing layer, providing excellent gas barrier, transparency, and bending resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a transparent gas barrier layer formed of metal oxide is stacked on a transparent plastic film by vapor deposition, ion plating, or sputtering, then gas barrier capability is improved, but cracks occur when the substrate is rounded or folded, causing gas barrier capability to deteriorate
Solution Approach 1:
The patent changes the physical and chemical parameters of the gas barrier layer by using a polymerizable composition containing silane-modified polyethylene and crosslinking agents. The crosslinking process creates a three-dimensional network structure that maintains gas barrier capability while providing flexibility and crack resistance during folding operations.
Solution Approach 2:
The patent employs a composite material system consisting of silane-modified polyethylene as the base polymer, crosslinking agents (such as borax or aluminum sulfate) to create the crosslinked network, and initiators for the polymerization reaction. This composite approach combines the gas barrier properties of the polymer matrix with the structural integrity provided by the crosslinked network.
2Reliability
If an inorganic compound layer is stacked on a plastic film to achieve gas barrier capability, then gas barrier performance is improved, but the process becomes complicated and production cost increases
Solution Approach 1:
The patent merges the gas barrier function with the plastic film substrate itself by incorporating silane-modified polyethylene into the polymer composition. This eliminates the need for separate inorganic compound layers, simplifying the overall structure and reducing production complexity while maintaining effective gas barrier capability.
Solution Approach 2:
The patent changes the chemical composition parameters of the plastic film by using silane-modified polyethylene that can undergo crosslinking reactions. This modification allows the film to achieve gas barrier properties through chemical crosslinking rather than requiring additional inorganic layers, thereby simplifying the manufacturing process.
3Weight of stationary object
If a transparent plastic film is used as a substrate instead of a glass sheet, then thickness and weight are reduced, but gas barrier capability deteriorates as steam and oxygen pass through
Solution Approach 1:
The patent changes the molecular structure and crosslinking density parameters of the plastic film to reduce gas permeability. By controlling the crosslinking degree and network structure of the silane-modified polyethylene, the film achieves low gas permeability while maintaining its lightweight and flexible characteristics.
Solution Approach 2:
The patent creates a composite structure within the plastic film itself by combining silane-modified polyethylene with crosslinking agents. This internal composite structure provides gas barrier functionality without requiring additional separate layers, maintaining the lightweight advantage of plastic films.
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 solution effectively enhances gas barrier and transparency while maintaining performance even when bent, reducing production complexity and costs compared to inorganic film deposition.
Implementation Method 1
a gas barrier layer that is formed of a material that includes at least an oxygen atom, a carbon atom, and a silicon atom
Implementation Method 2
a formed article that includes a gas barrier layer that is formed of a material that includes at least an oxygen atom, a carbon atom, and a silicon atom... having an oxygen atom content that gradually decreases from the surface of the gas barrier layer in the depth direction, and having a carbon atom content that gradually increases from the surface of the gas barrier layer in the depth direction
Data Source
AI summary
A formed article includes a gas barrier layer that is formed of a material that includes at least an oxygen atom, a carbon atom, and a silicon atom, the gas barrier layer having an oxygen atom content that gradually decreases from the surface of the gas barrier layer in the depth direction, and having a carbon atom content that gradually increases from the surface of the gas barrier layer in the depth direction. An electronic device member includes the formed article, and an electronic device includes the electronic device member. The formed article exhibits an excellent gas barrier capability and excellent transparency.