Laser-Carbonized Spacer Layer for Flexible Display Panel Bending
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Solution Overview
Problem
Metal traces in display panels are easily damaged by stress when the bending radius of the bonding area is small, leading to structural integrity issues.
Innovation Solution
A method for fabricating display panels involves forming a substrate with a bending area, a display area, and a bonding area, where a spacer layer is created by carbonizing an organic layer using laser irradiation, which spaces the first and second flexible layers, allowing for precise cutting and thinning of the substrate to prevent metal trace damage during bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the bending radius of the bonding area is reduced to achieve narrow frame products, then the width of the lower frame is effectively reduced, but the metal traces are easily damaged by stress
Solution Approach 1:
The patent applies preliminary action by pre-forming a spacer layer in the bending area before the bending process. This spacer layer is created by carbonizing an organic layer through laser irradiation, which establishes a protective structure that prevents metal trace damage during subsequent bending operations. The spacer layer is formed in advance to ensure metal trace integrity when the display panel is bent to achieve narrow frame dimensions.
2Reliability
If a spacer layer is formed by carbonizing an organic layer using laser irradiation, then the flexible layers are spaced and metal trace damage is prevented, but the manufacturing process complexity increases
Solution Approach 1:
The patent replaces mechanical or chemical carbonization methods with laser irradiation to form the spacer layer. The laser method provides precise control over the carbonization process, allowing the organic layer to be converted into a carbonized spacer layer with controlled thickness and properties. This substitution reduces process complexity compared to traditional mechanical or chemical methods while achieving the same protective function.
Solution Approach 2:
The patent utilizes parameter changes by controlling the laser irradiation parameters (wavelength, power, duration) to transform the organic layer into a carbonized spacer layer with specific properties. By adjusting these parameters, the process achieves optimal spacer layer formation for metal trace protection while managing manufacturing complexity. The organic layer material is selected to be easily carbonized under laser irradiation, facilitating controlled transformation.
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 method effectively prevents metal trace damage by creating a spacer layer that separates and spaces the flexible layers, allowing for controlled thinning of the substrate, thereby enhancing the structural integrity of the display panel during bending.
Implementation Method 1
irradiating the organic layer in the first setting area with a laser to make at least a portion of the organic layer a carbonized layer
Implementation Method 2
make at least a portion of the organic layer a carbonized layer, thereby forming a spacer layer
Implementation Method 3
the spacer layer comprises the carbonized layer formed by oxidizing the organic layer by irradiating light
Data Source
AI summary
A method for fabricating a display panel including a bending area includes: providing a substrate; forming a first flexible layer on the substrate; forming an organic layer on the first flexible layer, wherein a wavelength of light absorbed by the organic layer is different from a wavelength of light absorbed by the first flexible layer; irradiating a part of the organic layer in the bending area with a laser to make at least a portion of the part of the organic layer a carbonized layer, thereby forming a spacer layer; forming a second flexible layer covering the first flexible layer and the spacer layer, wherein the first flexible layer and the second flexible layer are made of a same material and separated by the spacer layer; and cutting a part of the substrate and a part of the first flexible layer in the bending area.