Stretchable Display Manufacturing Segmented Substrate
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Solution Overview
Problem
Conventional stretchable display manufacturing methods face challenges in achieving high reliability, economic efficiency, and minimizing image quality degradation, particularly in ensuring a stable substrate for mass production with excellent stretchability.
Innovation Solution
A method involving a flexible substrate with a light emitting layer and driving element, where a stretchable film with low and high stretchable areas is attached, with the high stretchable area covering the light emitting layer or wiring, and the low stretchable area covering the driving element, to provide enhanced stretchability and stability, using polyimide substrates and amorphous metal wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a substrate with excellent stretchability is used, then stretchability is improved, but reliability during light emitting layer deposition and driving element deposition is deteriorated
Solution Approach 1:
The substrate is segmented into two distinct regions: a first substrate region with low stretchability that provides stability during deposition, and a second substrate region with high stretchability that enables stretching functionality. This segmentation allows each region to fulfill its specific functional requirement independently.
Solution Approach 2:
Different regions of the substrate are assigned different mechanical properties (stretchability levels) according to their specific functional requirements. The first substrate region has low stretchability for stability, while the second substrate region has high stretchability for flexibility, creating local quality variation throughout the substrate structure.
2Adaptability or versatility
If a new stretchable substrate is developed, then stretchability is improved, but compatibility with mass production process is deteriorated
Solution Approach 1:
The substrate structure is designed to serve multiple functions: it maintains compatibility with existing flexible display mass production processes while simultaneously providing stretchability functionality. The first substrate region uses conventional materials and processes, enabling universal manufacturing compatibility.
3Reliability
If stretchable film is attached to cover driving element, then reliability in stretchable environment is improved, but device complexity is deteriorated
Solution Approach 1:
The stretchable film is attached to the second substrate region in advance, before the stretching operation is performed. This preliminary action ensures that the driving element is protected from stretching forces before they occur, maintaining reliability while simplifying the overall process sequence.
Data Source
AI summary
A method of manufacturing a stretchable display according to an embodiment of the present invention includes preparing a process carrier substrate, forming a flexible substrate on the process carrier substrate, forming a light emitting layer and a driving element controlling the light emitting layer on the flexible substrate, and attaching a stretchable film divided into a low stretchable area and a high stretchable area such that at least a part of the low stretchable area covers at least a part of the driving element in a state in which the high stretchable area is stretched.