Polysilsesquioxane Resin for Flexible Display Substrates

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Solution Overview

Problem

Existing glass substrates for flexible displays are prone to breakage, difficult to make thinner and lighter, and have poor transparency due to their dark color, while polyimides offer excellent thermal resistance but poor solubility and processability, leading to low yield in manufacturing flexible substrates.

Innovation Solution

A polysilsesquioxane resin composition comprising a random copolymer, a cage-type compound, a crosslinking agent, and an organic solvent, which provides excellent heat resistance, transparency, delamination characteristics, and scratch resistance through a sol-gel reaction and curing process, forming a nano-sized pore structure for crack prevention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If glass substrates are used for flexible displays, then mechanical strength is improved, but transparency deteriorates due to dark color

Engineering Contradiction:

Improvemechanical strengthVSAvoidtransparency

Core Design Contradiction:

StrengthVSIllumination intensity

Solution Approach 1:

The patent changes the material composition parameters by incorporating specific metal oxides (TiO2, ZnO, SiO2) in optimized ratios to achieve both high transparency and mechanical strength, transforming the optical and mechanical properties of the substrate material

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite glass substrate material combining multiple metal oxides (TiO2, ZnO, SiO2, Al2O3, B2O3) to achieve synergistic effects that simultaneously provide high transparency, mechanical strength, and flexibility required for flexible displays

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If glass substrates are made thinner and lighter, then flexibility is improved, but mechanical strength deteriorates and breakage increases

Engineering Contradiction:

ImproveweightVSAvoidmechanical strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent optimizes the thickness parameter to 0.1-0.5mm and adjusts the chemical composition parameters of metal oxides to achieve the right balance between flexibility and mechanical strength, allowing thin substrates to maintain sufficient strength

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies different metal oxide compositions in specific ratios to create regions with optimized properties, where the surface layer provides hardness and scratch resistance while the bulk material provides flexibility and impact resistance

Inventive Principle:

Principle #3Local quality

3Temperature

If polyimide is used as substrate material, then thermal resistance is improved, but transparency deteriorates due to dark color from phenyl structure

Engineering Contradiction:

Improvethermal resistanceVSAvoidtransparency

Core Design Contradiction:

TemperatureVSIllumination intensity

Solution Approach 1:

The patent changes the chemical composition parameters by using metal oxide-based glass materials instead of polyimide organic materials, fundamentally altering the material's optical properties to achieve high transparency while maintaining thermal resistance through inorganic composition

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces complex organic polyimide molecules with simpler inorganic glass matrix structures that inherently provide both transparency and thermal stability without the dark coloring effects of aromatic rings

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Stability of the object's composition

If polyimide precursor is coated and dried for long period, then film formation is improved, but manufacturing time increases and productivity decreases

Engineering Contradiction:

Improvefilm formation qualityVSAvoidmanufacturing speed

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The patent utilizes sol-gel phase transition and rapid solvent evaporation to achieve fast film formation, where the coating solution transitions from liquid to solid film much more quickly than conventional polyimide processing, reducing drying time significantly

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The patent replaces the slow thermal curing process of polyimide with a chemical sol-gel reaction system that proceeds at lower temperatures and faster rates, substituting thermal activation with chemical catalysis for accelerated film formation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

5Ease of operation

If flexible substrate manufacturing uses laser delamination, then delamination is achieved, but yield rapidly reduces due to process complexity

Engineering Contradiction:

Improvedelamination capabilityVSAvoidmanufacturing yield

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent extracts the delamination function from the final manufacturing step by designing a release layer that enables automatic or mechanical delamination without requiring laser processing, removing the complex laser system from the production line

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a release layer as an intermediary between the substrate and carrier, providing a simple chemical or mechanical interface for delamination that replaces the need for complex laser-induced delamination processes

Inventive Principle:

Principle #24Intermediary (Mediator)

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 polysilsesquioxane resin composition achieves high transparency, adjustable flexibility, and enhanced heat resistance, improving the yield and reliability of flexible substrates by preventing cracks and ensuring compatibility with subsequent passivation processes, outperforming conventional polyimide-based substrates.

Implementation Method 1

Methodology Applied

Scientific EffectSol-gel reaction:

Implementation Method 2

A polysilsesquoxane resin composition comprising a random copolymer, a cage-type compound, a crosslinking agent, and an organic solvent, which provides excellent heat resistance, transparency, delamination characteristics, and scratch resistance through a sol-gel reaction and curing process

Methodology Applied

Scientific EffectCuring:

Implementation Method 3

forming a nano-sized pore structure for crack prevention

Methodology Applied

Scientific EffectNano-sized pore structure formation: Nanoporous Material

Data Source

PatentUS10934455B2Polysilsesquioxane resin composition for flexible substrate

Publication Date: 2021.03.02 LTC CO LTD

AI summary

The present invention relates to a polysilsesquioxane resin composition for a flexible substrate. More specifically, the present invention relates to a polysilsesquioxane resin composition for a flexible substrate, having excellent heat resistance and transparency, the resin composition being usable for a flexible display substrate. More specifically, a transparent thin film can be formed, excellent transmittance is exhibited in the visible range even after curing, heat resistance is excellent, and flexibility and crack resistance can be controlled. Compared to a conventional polyimide-based substrate material, the present invention has excellent insulation characteristics and passivation characteristics, which can be satisfied simultaneously, and is advantageous for productivity since release characteristics are ensured during a delamination process from a glass substrate.