Inorganic Rib Layers for Flexible Display Substrate Separation

Solution Overview

Problem

Existing methods for manufacturing flexible display devices face challenges in cutting resin substrates laminated on glass substrates, as they are difficult to break along grooves, leading to issues in separating display regions without damaging the substrates.

Innovation Solution

A method involving the formation of inorganic rib layers and protection films around resin layers, allowing for the separation of display regions by cutting along the rib layers while avoiding the resin layers, which are made of materials with higher moistureproof properties than the resin layers themselves.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If glass substrates are broken along grooves to separate display regions, then cutting is achieved, but the method fails when resin substrates are laminated on glass substrates as they are hard to break

Engineering Contradiction:

Improveease of cutting substratesVSAvoidapplicability to resin-laminated substrates

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The substrate structure is segmented into distinct functional regions: a resin layer for flexibility, inorganic rib layers for structural support and cutting, and glass substrates for base stability. This segmentation allows each layer to perform its specialized function, enabling the overall structure to be cut through the inorganic rib layers while preserving the resin layer integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inorganic rib layers serve as intermediary elements between the resin layer and glass substrates. These rib layers act as a mediator that can be selectively removed or cut, facilitating substrate separation without directly compromising the resin layer, which would be difficult to cut if exposed.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If resin layers are cut to separate display regions, then separation is achieved, but the resin layers are difficult to cut when laminated on glass substrates

Engineering Contradiction:

Improveefficiency of substrate separationVSAvoidease of cutting resin layers

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The substrate structure is segmented into distinct functional regions: a resin layer for flexibility, inorganic rib layers for structural support and cutting, and glass substrates for base stability. This segmentation allows each layer to perform its specialized function, enabling the overall structure to be cut through the inorganic rib layers while preserving the resin layer integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inorganic rib layers serve as intermediary elements between the resin layer and glass substrates. These rib layers act as a mediator that can be selectively removed or cut, facilitating substrate separation without directly compromising the resin layer, which would be difficult to cut if exposed.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If thicker protection films are used to prevent moisture permeation, then moistureproofing is improved, but the device structure becomes more complex

Engineering Contradiction:

Improvemoistureproof performanceVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs a composite moisture barrier structure combining organic resin layers with inorganic rib layers. This composite approach leverages the complementary properties of both materials: the resin provides baseline protection while the inorganic ribs add enhanced moisture blocking capability at critical locations, achieving superior moistureproof performance without uniform thickness increase throughout the entire device.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Instead of uniformly increasing protection film thickness across the entire device, the inorganic rib layers are strategically positioned at specific locations where moisture infiltration risk is highest. This local quality enhancement provides targeted moisture protection while minimizing overall structural complexity and material usage.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9978989B2Method of fabricating display device ring shape rib layer

Publication Date: 2018.05.22 MAGNOLIA WHITE CORP

AI summary

First rib layers made of an inorganic material are formed in first frame regions of a first glass substrate. First resin layers are formed in first product regions after the first rib layers are formed. First functional layers which include light emitting element layers as a result of luminance of each of unit pixels forming an image being controlled and sealing layers covering the light emitting element layers are formed on the first rib layers and the first resin layers. The first rib layers and the first functional layers are cut along lines passing through the first frame regions while avoiding the first product regions in order to separate the first product regions from each other. In the step of cutting the first rib layers and the first functional layers, the first rib layers and the sealing layers are cut.