Stacked Conductive Films with Oxygen Gradients for Foldable Displays
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Solution Overview
Problem
Existing display devices face challenges in preventing the loss of organic films during the etching process of conductive layers, particularly in foldable and bendable display devices, where the structural integrity and reliability of the conductive patterns are crucial for maintaining the device's functionality across various states.
Innovation Solution
The implementation of a conductive layer structure with a first conductive film having a higher oxygen concentration than the second conductive film, allowing for controlled etching rates and preventing oxidation, thereby minimizing the loss of organic films during the etching process. This structure includes multiple stacked films with specific etching processes using different etchants to form distinct conductive patterns, ensuring reliable etching without compromising the integrity of underlying layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a single conductive layer structure is used, then the manufacturing process is simple, but the organic film loss during etching cannot be effectively prevented
Solution Approach 1:
The conductive layer is divided into multiple stacked films (first conductive film, second conductive film, third conductive film) with different oxygen concentrations. This segmentation allows selective etching where the first conductive film with higher oxygen concentration protects the organic film underneath, while upper conductive films can be etched without causing organic film loss.
Solution Approach 2:
The patent uses a composite conductive layer structure combining multiple materials with different oxygen concentrations. The first conductive film (higher oxygen concentration) serves as a protective barrier layer, while upper conductive films (lower oxygen concentration) provide additional conductivity. This composite structure resolves the contradiction by providing both protection and functionality.
2Manufacturing precision
If etching is performed on conductive layers, then conductive patterns are formed, but organic film loss occurs
Solution Approach 1:
The first conductive film with higher oxygen concentration is formed at the bottom of the conductive layer stack before etching operations. This preliminary protective layer is in place before any etching occurs, preventing organic film loss during subsequent etching of upper conductive films while allowing precise conductive pattern formation.
Solution Approach 2:
The first conductive film acts as an intermediary protective barrier between the etching process and the organic film. It mediates the etching process by absorbing or preventing damage to the organic film while allowing the formation of precise conductive patterns in the upper layers.
3Area of moving object
If foldable and bendable display structures are used, then larger screen is provided, but structural integrity of conductive layers is compromised
Solution Approach 1:
The multi-layer conductive structure with varying oxygen concentrations provides enhanced structural integrity for foldable and bendable displays. The first conductive film with higher oxygen concentration acts as a protective barrier that maintains integrity during folding and bending, while upper conductive films provide additional mechanical strength and conductivity.
Solution Approach 2:
The patent addresses the structural challenges of foldable and bendable displays by creating a conductive layer structure that can accommodate curvature and folding. The stacked film structure with different oxygen concentrations provides flexibility and structural integrity, allowing the display to maintain functionality in folded and bent states while preserving conductive layer integrity.
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 approach effectively prevents the loss of organic films during etching, maintains the structural integrity of conductive layers, and ensures reliable performance across folded and unfolded states of the display device, enhancing the durability and functionality of foldable and bendable displays.
Implementation Method 1
the first conductive film has an oxygen concentration higher than an oxygen concentration of the second conductive film
Implementation Method 2
etching the second conductive film using a first etchant to form a second conductive pattern; and etching the first conductive film using a second etchant different from the first etchant to form a first conductive pattern
Data Source
AI summary
A display device includes a base substrate; an organic layer disposed on the base substrate; and a first conductive layer disposed on the organic layer, wherein the first conductive layer includes a plurality of stacked films, the plurality of stacked films include a first conductive film disposed directly on the organic layer and a second conductive film disposed on the first conductive film, and the first conductive film has an oxygen concentration higher than an oxygen concentration of the second conductive film.