Silane Primer Layer for Flexible Display Gas Barrier Adhesion
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Solution Overview
Problem
Existing flexible display technologies using synthetic resin sheets face issues with gas barrier performance due to poor interlayer adhesion between the flattening layer and the gas barrier layer, leading to increased thickness and production complexity, and insufficient gas barrier capability unless the gas barrier layer thickness is significantly increased.
Innovation Solution
A formed article comprising a base layer, a primer layer with specific silicon and oxygen content, and a gas barrier layer formed by ion implantation into a polymer layer containing polysilazane, polyorganosiloxane, or polycarbosilane compounds, achieving excellent interlayer adhesion and gas barrier properties without the need for thick layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a gas barrier inorganic compound thin film is stacked on a flattening layer formed on a synthetic resin sheet, then gas barrier capability is improved, but interlayer adhesion between the flattening layer and gas barrier layer deteriorates
Solution Approach 1:
The patent introduces a primer layer as an intermediary between the flattening layer and the gas barrier layer. This primer layer contains silane coupling agents that chemically bond to both the inorganic flattening layer and the inorganic gas barrier layer, thereby improving interlayer adhesion while maintaining gas barrier capability.
Solution Approach 2:
The patent uses composite material structure where the primer layer combines organic silane coupling agents with inorganic oxide components. This composite approach allows the primer layer to serve dual functions: bonding to both adjacent layers and providing a foundation for good gas barrier adhesion.
2Reliability
If a functional thin film is added to improve interlayer adhesion, then interlayer adhesion is improved, but the thickness of the gas barrier sheet increases
Solution Approach 1:
The patent employs a thin primer layer (typically 1-10 nm) that provides adequate adhesion improvement without significantly increasing overall thickness. The silane-based primer forms a molecular-level interface layer that is thin yet functionally effective.
3Object-affected harmful factors
If the thickness of the gas barrier layer is increased to micrometer level, then gas barrier capability is improved, but the number of production steps increases
Solution Approach 1:
The patent changes the chemical composition parameters of the primer layer by incorporating silane coupling agents with specific functional groups. This compositional change enables effective adhesion at much thinner dimensions, avoiding the need for thick gas barrier layers and complex multi-step production processes.
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 flexible display with enhanced interlayer adhesion, gas barrier capability, and transparency, suitable for applications like solar cells and touch panels, while simplifying production and reducing costs.
Implementation Method 1
a gas barrier layer which is a layer obtained by implanting ions into a polymer layer that includes at least one compound selected from a group consisting of a polysilazane compound, a polyorganosiloxane compound, a polycarbosilane compound, and a polysilane compound
Data Source
AI summary
The present invention is a formed article sequentially including a base layer, a primer layer, and a gas barrier layer, the primer layer being formed of a material that includes at least a carbon atom, an oxygen atom, and a silicon atom, and is characterized in that a peak position of binding energy of 2p electrons of the silicon atom as determined by X-ray photoelectron spectroscopy (XPS) is 101.5 to 104 eV, and the gas barrier layer (I) being a layer obtained by implanting ions into a polymer layer that includes at least one compound selected from a group consisting of a polysilazane compound, a polyorganosiloxane compound, a polycarbosilane compound, and a polysilane compound, or (II) being formed of a material that includes at least an oxygen atom and a silicon atom, a surface layer part of the gas barrier layer having an oxygen atom content rate of 60 to 75%, a nitrogen atom content rate of 0 to 10%, and a silicon atom content rate of 25 to 35%, based on a total content rate of oxygen atoms, nitrogen atoms, and silicon atoms, and the surface layer part of the gas barrier layer having a film density of 2.4 to 4.0 g/cm3. Also provided are a method for forming the same, an electronic device member including the formed article, and an electronic device including the electronic device member.