Sacrificial Layer Segmentation for Flexible Display Substrate Separation
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Solution Overview
Problem
Flexible display devices face challenges in the separation process from support substrates due to untreated sacrificial layers caused by foreign materials, leading to defects such as bright and dark spots in the final display.
Innovation Solution
A sacrificial layer with a higher hydrogen content, formed in a multi-layered structure including a barrier layer and a separation layer, is used to facilitate separation by irradiating a laser through the support substrate, increasing the internal pressure and reducing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a sacrificial layer is used to facilitate separation of the flexible substrate from the support substrate, then the separation process becomes easier, but foreign materials on the support substrate prevent sufficient treatment of the sacrificial layer by laser beam, leading to defects
Solution Approach 1:
The sacrificial layer is divided into multiple sub-layers with different hydrogen contents. The first sub-layer has higher hydrogen content to generate sufficient internal pressure for complete separation, while the second sub-layer has lower hydrogen content to prevent excessive gas generation. This segmentation resolves the contradiction by ensuring reliable separation even when foreign materials are present on the support substrate.
Solution Approach 2:
The patent changes the hydrogen content parameter across different sub-layers of the sacrificial layer. By creating a gradient of hydrogen content (higher in the first sub-layer, lower in the second), the laser treatment effectiveness is improved without causing excessive gas generation, thus resolving the contradiction between ease of separation and separation quality.
2Ease of operation
If the hydrogen content in the sacrificial layer is increased to improve separation, then separation effectiveness increases, but excessive hydrogen may cause unwanted side effects
Solution Approach 1:
Different regions (sub-layers) of the sacrificial layer are assigned different hydrogen contents based on their specific functions. The first sub-layer has higher hydrogen content localized to provide sufficient separation force, while the second sub-layer has lower hydrogen content localized to prevent excessive gas generation. This local quality differentiation resolves the contradiction between separation effectiveness and harmful side effects.
Solution Approach 2:
The sacrificial layer is constructed as a composite structure with multiple sub-layers having different material compositions and hydrogen contents. This composite approach allows the system to achieve both high separation effectiveness (from the high-hydrogen first sub-layer) and controlled gas generation (from the low-hydrogen second sub-layer), resolving the contradiction.
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 method effectively reduces defects and enhances the reliability of the separation process, allowing for the formation of high-quality flexible display devices even with foreign materials present on the support substrate.
Implementation Method 1
irradiating a laser beam onto the rear surface of the support substrate to treat the sacrificial layer
Implementation Method 2
the sacrificial layer may not be sufficiently treated by the laser beam
Implementation Method 3
A sacrificial layer with a higher hydrogen content, formed in a multi-layered structure including a barrier layer and a separation layer, is used to facilitate separation by irradiating a laser through the support substrate, increasing the internal pressure
Data Source
AI summary
Disclosed is a flexible display device and method of manufacturing the same in which a method of manufacturing a flexible display device may include forming a sacrificial layer on a support substrate, the sacrificial layer including at least one barrier layer and a separation layer, the barrier layer having a higher hydrogen content than that of the separation layer; forming a first flexible substrate on the support substrate provided with the sacrificial layer; forming a plurality of device elements on the first flexible substrate; and irradiating a laser onto the sacrificial layer through the support substrate and separating the support substrate from the first substrate.