Plastic Substrate with Symmetrical Hybrid Buffer Layers
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Solution Overview
Problem
Conventional plastic substrates with multi-layer structures fail to achieve a small coefficient of thermal expansion and superior gas barrier properties necessary for replacing glass substrates in display devices, often experiencing deformation or cracking due to differences in thermal expansion coefficients between layers.
Innovation Solution
A plastic substrate with a multi-layer structure comprising plastic films sandwiched between symmetrical arrangements of organic-inorganic hybrid buffer layers and gas barrier layers, which minimizes thermal expansion differences and enhances adhesion, is developed. The method involves forming organic-inorganic hybrid buffer layers and gas barrier layers on plastic films, with the buffer layers improving adhesion and reducing surface defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an inorganic gas barrier layer is directly coated on a plastic film, then gas barrier properties are improved, but the plastic film deforms or the inorganic layer cracks or peels due to coefficient of thermal expansion mismatch
Solution Approach 1:
An organic-inorganic hybrid buffer layer is introduced as an intermediary between the plastic film and the inorganic gas barrier layer. This buffer layer has a coefficient of thermal expansion that gradually transitions from the plastic film to the inorganic layer, reducing thermal stress and preventing deformation, cracking, or peeling while maintaining excellent gas barrier properties.
Solution Approach 2:
The patent uses composite materials consisting of organic and inorganic components in the buffer layer. This composite structure combines the flexibility and adhesion of organic materials with the barrier properties of inorganic materials, creating a multi-functional layer that resolves the contradiction between gas barrier performance and dimensional stability.
2Stability of the object's composition
If glass substrates are used for display devices, then dimensional stability and gas barrier properties are improved, but weight increases and impact resistance decreases
Solution Approach 1:
The patent changes the fundamental material parameter from inorganic (glass) to organic polymer, fundamentally altering the weight and impact resistance characteristics while maintaining dimensional stability through the multi-layer structure design. The plastic film base provides lightweight and impact-resistant properties.
3Weight of stationary object
If a single polymer composite film is used, then weight and ease of design are improved, but gas barrier properties and dimensional stability are insufficient
Solution Approach 1:
The patent segments the substrate into multiple functional layers: a plastic film base layer providing lightweight and impact resistance, an organic-inorganic hybrid buffer layer providing adhesion and stress management, and an inorganic gas barrier layer providing excellent gas barrier properties. This segmentation allows each layer to optimize its specific function.
Solution Approach 2:
The patent employs composite materials at multiple levels: the organic-inorganic hybrid buffer layer combines organic polymer and inorganic filler particles, and the overall structure combines organic plastic film with inorganic gas barrier layer, achieving superior integrated performance.
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 plastic substrate with a small coefficient of thermal expansion, excellent dimensional stability, and superior gas barrier properties, enabling it to replace glass substrates in display devices while maintaining mechanical strength and transparency.
Implementation Method 1
deformation of the plastic film or cracking or peeling of the inorganic layer may occur because of the difference of coefficients of linear expansion of the plastic film and the gas barrier layer
Implementation Method 2
an inorganic barrier layer for blocking gaseous materials such as oxygen and water vapor
Data Source
AI summary
The present invention relates to a plastic substrate having a multi-layer structure and a method for preparing the same. The plastic substrate of the present invention comprises plastic films attached to each other, and a first buffering layer of an organic-inorganic hybrid, a layer of gas barrier, and a second buffering layer of an organic-inorganic hybrid which are stacked on both sides of the plastic films in an orderly manner, each layer forming a symmetrical arrangement centering around the plastic films.Because the plastic substrate of the present invention has a small coefficient of thermal expansion, excellent dimensional stability, and superior gas barrier properties, it can replace the brittle and heavy glass substrate in display devices. Also, it can be used for a variety of packaging or container materials in applications requiring superior gas barrier properties.