Stretchable Display Panel With Segmented Encapsulation Layer
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Solution Overview
Problem
The continuity of encapsulation layers in existing flexible display panels affects their stretchable performance, leading to cracking and reduced display quality during the laser lift-off process, which compromises the panel's ability to be effectively stretched.
Innovation Solution
A display panel design featuring a rigid substrate with a flexible substrate having through-groove structures, where an organic separation layer is used to separate the encapsulation layer, allowing the rigid substrate to be lifted off with an external force, thereby improving stretchable performance and reducing stress on the encapsulation layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the encapsulation layer is made continuous in through-groove structures, then the structural integrity is improved, but the stretchable performance deteriorates due to cracking during laser lift-off
Solution Approach 1:
The encapsulation layer in the through-groove structure is segmented into multiple independent portions rather than being continuous. Each portion is independently supported by the rigid substrate, preventing stress concentration and cracking during laser lift-off, thus maintaining both structural integrity and stretchable performance
Solution Approach 2:
An organic separation layer is introduced as an intermediary between the encapsulation layer and the rigid substrate in the through-groove structure. This layer allows controlled separation during laser lift-off, enabling the encapsulation layer to be released without cracking while maintaining its integrity
2Object-affected harmful factors
If the encapsulation layer is continuously formed over the rigid substrate, then the protection function is improved, but the laser lift-off process causes cracking and reduces display quality
Solution Approach 1:
The encapsulation layer is segmented into discrete portions within the through-groove structures, with each portion independently protected. This segmentation allows the laser to selectively remove the organic separation layer without causing stress-induced cracking, maintaining both protection function and display quality
Solution Approach 2:
The organic separation layer is extracted or removed through laser gasification in the through-groove regions. This extraction enables the encapsulation layer portions to be released from the rigid substrate without the harmful continuous attachment, preventing cracking while maintaining protection
3Reliability
If the organic separation layer is used to separate the encapsulation layer, then the stretchable performance is improved, but the manufacturing process complexity increases
Solution Approach 1:
The organic separation layer serves as a temporary intermediary that enables stretchable performance. It is deposited as a patterned layer in the through-groove structures, providing controlled separation during laser lift-off. The layer is fully removed after serving its purpose, leaving no residual complexity in the final product
Solution Approach 2:
The organic separation layer utilizes material parameter changes under laser irradiation (gasification) to achieve separation. This parameter change allows the layer to transition from a bonded state to a removed state, enabling stretchable performance through a controllable manufacturing process
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
This design enhances the stretchable performance of the display panel by ensuring the encapsulation layer's integrity is maintained, reducing the likelihood of cracking and improving display quality by allowing controlled separation and lifting off of the encapsulation layer components.
Implementation Method 1
acting on the rigid substrate through a laser lift-off process, and gasifying the organic separation layer to separate the second sub-portion from the rigid substrate
Implementation Method 2
forming a plurality of through-groove structures on the flexible substrate through a photoetching process
Data Source
AI summary
Disclosed are a display panel, a manufacturing method and a stretchable display device. The display panel includes a rigid substrate; a flexible substrate and an encapsulation layer. The flexible substrate includes a plurality of through-groove structures and at least one through-groove structure includes a non-fixed region and a fixed region surrounding the non-fixed region. A portion of the encapsulation layer located in the at least one through-groove structure includes a first sub-portion located in the fixed region and attached to the rigid substrate and a second sub-portion located in the non-fixed region and attached to the rigid substrate by an organic separation layer, the second sub-portion is configured to be separated from the rigid substrate in a case of gasification of the organic separation layer, and the first sub-portion is configured to be lifted off from the flexible substrate together with the rigid substrate under an external force.