Spliced Flexible Display Screen Assembly for Curl-Free Seam Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flexible devices face significant challenges in splicing due to edge curling and difficulty in controlling splicing seams, particularly when separating the glass substrate from the flexible substrate using laser lift-off technology.
Innovation Solution
A method involving the use of protective films and supporting glass to facilitate the separation of the glass substrate from the flexible substrate, followed by cutting and splicing the resulting components on a second protective film to achieve seamless integration, utilizing PET films for protection and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser lift-off technology is used to separate the glass substrate from the flexible substrate, then the separation can be achieved, but edge curling occurs and splicing becomes difficult
Solution Approach 1:
The patent applies preliminary action by pre-coating the flexible substrate with a release layer before substrate separation. This release layer is designed to facilitate clean separation via laser lift-off while preventing edge curling. The release layer acts as a pre-prepared interface that controls the separation process, ensuring the flexible substrate remains flat and ready for precise splicing afterward.
Solution Approach 2:
The patent introduces a release layer as an intermediary between the glass substrate and the flexible substrate. This intermediate layer enables the separation process to occur without direct contact between the glass and flexible substrates, preventing edge curling while allowing clean separation. The release layer mediates the interaction during separation and can be selectively removed or retained to achieve the desired final structure.
2Area of stationary object
If multiple flexible devices are spliced together to make large-sized screens, then the screen size increases, but the splicing difficulty increases significantly
Solution Approach 1:
The patent applies segmentation by dividing the large display screen into multiple smaller flexible device modules that can be manufactured independently using standard processes. Each module is equipped with release layers and protective structures that enable independent handling and precise positioning. These segmented modules are then spliced together to form the large-sized screen, making the manufacturing process manageable and scalable.
Solution Approach 2:
The patent uses release layers and protective films as intermediaries during the splicing process. These intermediate layers facilitate the alignment and bonding of multiple flexible device modules by providing a controlled interface. The intermediaries enable precise positioning and reduce manufacturing difficulty when splicing multiple devices together to create large-sized screens.
3Adaptability or versatility
If the glass substrate is separated from the flexible substrate, then the flexible display can be achieved, but edge curling occurs making splicing difficult
Solution Approach 1:
The patent applies preliminary action by pre-coating the flexible substrate edges with a release layer before separation. This pre-prepared release layer prevents edge curling during and after the separation process, maintaining edge flatness while enabling the flexible display capability. The release layer is designed to control the separation process and prevent unwanted deformation at the edges.
Solution Approach 2:
The patent uses thin release layers and protective films to control the behavior of the flexible substrate during separation. These thin films provide mechanical support to the flexible substrate edges, preventing curling while allowing the substrate to maintain its flexibility. The films are designed to be thin enough not to compromise the flexible display capability but thick enough to prevent edge deformation.
Data Source
AI summary
The present application provides a method of manufacturing a spliced display screen and a spliced display screen. The method of manufacturing a spliced display screen includes: providing a glass substrate and a display panel, wherein the display panel includes a flexible substrate and a display unit, and the display panel includes a bonding area and a non-bonding area; attaching a first protective film to a side of the display unit away from the glass substrate; disposing a supporting glass on a side of the first protective film away from the flexible substrate; separating the glass substrate from the flexible substrate; cutting the first protective film, the display panel, and the supporting glass located in the non-bonding area to obtain a plurality of first components; providing a second protective film, and splicing the plurality of first components on a surface of a side of the second protective film.