Multilayered Plastic Substrate with Hybrid Buffer Layers for Thermal Stability
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Solution Overview
Problem
Current multilayered plastic substrates face challenges in achieving high temperature thermal deformation resistance, low linear expansion coefficient, and excellent dimensional stability while maintaining gas barrier properties, often experiencing issues like cracking and stripping due to differences in linear expansion coefficients between layers.
Innovation Solution
A multilayered plastic substrate structure is developed, featuring a polymer base with first and second buffer layers that are UV and thermally cured, and a gas barrier layer, which are sequentially applied to address the issues of thermal deformation and gas barrier properties, and a method for manufacturing this substrate that includes UV curing and thermal curing steps to ensure proper layer attachment and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an inorganic material gas barrier layer is coated on a polymer base, then gas barrier property is improved, but the polymer base may be deformed and cracks may be generated due to large difference in linear expansion coefficients
Solution Approach 1:
The patent introduces a buffer layer composed of organic-inorganic hybrid material between the polymer base and the inorganic gas barrier layer. This intermediary layer has a linear expansion coefficient intermediate between the polymer base and the inorganic layer, thereby reducing the thermal expansion mismatch and preventing deformation and cracking while maintaining gas barrier properties.
Solution Approach 2:
The patent uses organic-inorganic hybrid materials for the buffer layer, combining the advantages of both organic materials (flexibility, adhesion to polymer) and inorganic materials (low linear expansion coefficient, thermal stability). This composite approach enables the buffer layer to bridge the mechanical and thermal properties between the polymer base and the inorganic gas barrier layer.
2Reliability
If multiple coating layers are applied to satisfy physical properties, then functional requirements are met, but the manufacturing process becomes complex
Solution Approach 1:
The buffer layer is designed to perform multiple functions simultaneously: it acts as an adhesive layer for attachment between the polymer base and gas barrier layer, serves as a stress buffer to reduce thermal expansion mismatch, provides a flat surface for subsequent coating, and contributes to the overall mechanical strength. This multi-functionality reduces the need for separate specialized layers, simplifying the manufacturing process.
3Reliability
If getter particles are dispersed on plastic substrate to block oxygen and steam, then gas barrier property is improved, but the substrate thickness must be increased to include sufficient particles
Solution Approach 1:
The patent incorporates inorganic particles (such as silica, alumina, or titania nanoparticles) within the organic-inorganic hybrid buffer layer. These particles create a tortuous path for gas molecules, significantly enhancing the gas barrier properties of the thin buffer layer without requiring increased substrate thickness. The porous or particulate structure provides effective gas blocking at minimal thickness.
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 provides a substrate with improved high temperature thermal deformation resistance, low linear expansion coefficient, and excellent dimensional stability, effectively replacing glass substrates in display devices and other applications requiring gas barrier properties.
Implementation Method 1
first buffer layers that are disposed on upper and lower sides of the polymer base and include a cured material by UV curing and thermal curing of a buffer composition capable of being UV cured and thermal cured
Implementation Method 2
first buffer layers that are disposed on upper and lower sides of the polymer base and include a cured material by UV curing and thermal curing of a buffer composition capable of being UV cured and thermal cured
Data Source
AI summary
The present invention provides a multilayered plastic substrate that simultaneously satisfies improvement in high temperature thermal deformation according to low linear expansion coefficient and excellent dimensional stability and excellent gas barrier property, and is capable of being used instead of a glass substrate that has brittleness and heavy disadvantages without a problem caused by a difference in linear expansion coefficient between layers, and a method for manufacturing the same.