Resin Substrate Orthogonal Layers Crack Prevention
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Solution Overview
Problem
Existing resin substrates for display devices face reliability issues due to cracking, particularly when subjected to warping, which compromises their waterproof properties and overall performance.
Innovation Solution
A resin substrate configuration featuring a first resin layer with a specific long-axis direction, an intermediate inorganic layer, and a second resin layer with a slanted long-axis direction, preventing cracks from penetrating through the substrate by aligning the polymer resin layers perpendicularly to the warping directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a resin substrate is used for display devices, then flexibility and lightweight properties are improved, but reliability deteriorates due to crack occurrence during warping
Solution Approach 1:
The patent applies composite materials by combining multiple resin layers (first resin layer and second resin layer) with different long-axis directions. This composite structure prevents cracks from penetrating through the entire substrate during warping, as the orthogonal fiber orientations distribute and block crack propagation paths, thereby improving reliability while maintaining the lightweight property of resin substrates.
2Reliability
If polymer resin layers are oriented perpendicular to warping directions, then crack penetration is prevented, but manufacturing complexity increases due to precise orientation control requirements
Solution Approach 1:
The patent employs asymmetry by orienting the long-axis directions of the first and second resin layers perpendicular to each other (orthogonal arrangement). This asymmetric orientation pattern creates a cross-like structure that effectively blocks crack propagation in multiple directions during substrate warping, achieving high crack resistance without requiring complex manufacturing processes.
3Reliability
If multiple resin layers with different orientations are used, then waterproof properties are maintained during warping, but the number of layers and manufacturing steps increase
Solution Approach 1:
The patent uses composite materials with two resin layers having orthogonal long-axis directions. This composite structure maintains waterproof properties during warping by preventing crack penetration through the substrate, as the perpendicular fiber orientations block moisture pathways. The two-layer design achieves effective crack and moisture barrier functionality without excessive complexity.
Data Source
AI summary
Reliability of a resin substrate is further enhanced. A first resin layer is made of polymer resin having a long-axis direction. A second resin layer is made of polymer resin having a long-axis direction slanted with respect to the long-axis direction in a plan view.