Stretchable Display Substrate With Step-Like Opening Patterns
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Solution Overview
Problem
Existing stretchable OLED display elements face reliability issues due to poor encapsulation of the side surfaces of the display units, leading to moisture ingress and decreased reliability.
Innovation Solution
A stretchable display substrate is designed with a base substrate featuring opening patterns with step-like structures, allowing for a thin film encapsulation layer that is interrupted at these structures. This design ensures that the encapsulation layer is preserved on the side surfaces of the display units during the Laser Lift Off process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional encapsulation layer is used without step-like structures, then the manufacturing process is simpler, but the encapsulation reliability is poor and moisture ingress occurs
Solution Approach 1:
The base substrate is divided into multiple opening patterns with step-like structures, creating distinct regions (first opening region and second opening region) that segment the encapsulation layer into different portions. This segmentation allows the first encapsulation layer to be selectively retained on the side surface while the second encapsulation layer is removed, solving the contradiction between encapsulation reliability and structural complexity.
Solution Approach 2:
Different regions of the opening pattern are given different opening sizes to create local quality variations. The first opening region has a different opening size than the second opening region, which allows the encapsulation layer to be differentially retained or removed in different areas. This local quality approach enables selective encapsulation retention to improve reliability without requiring complete structural redesign.
2Reliability
If the encapsulation layer is continuously formed without interruptions, then the manufacturing process is easier, but the encapsulation layer is peeled off during Laser Lift Off process
Solution Approach 1:
The step-like structures are formed in advance on the base substrate before the encapsulation layers are deposited. This preliminary action creates predetermined interruption points that guide the selective removal process during Laser Lift Off, ensuring the encapsulation layer is retained in critical areas without requiring complex real-time control during the lift-off process.
Solution Approach 2:
The step-like structures act as intermediary elements between the base substrate and the encapsulation layers. These intermediate structures provide a physical basis for selective encapsulation retention, mediating the interaction between the laser processing and the encapsulation layer to achieve differential removal while maintaining manufacturing feasibility.
3Reliability
If opening patterns have uniform sizes, then the manufacturing process is simpler, but the encapsulation cannot be selectively controlled on side surfaces
Solution Approach 1:
The opening patterns are designed with asymmetric characteristics through the step-like structures, where the first opening region and second opening region have different opening sizes. This asymmetry enables selective control of the encapsulation layer, allowing it to be retained on the side surface in the first region while being removed in the second region, thus improving side surface encapsulation reliability.
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 proposed solution enhances the encapsulation reliability of stretchable display substrates by preventing the encapsulation layer from being peeled off during the Laser Lift Off process, thereby reducing moisture ingress and improving the overall reliability of the display element.
Implementation Method 1
the encapsulation layer is preserved on the side surfaces of the display units during the Laser Lift Off process
Data Source
AI summary
The present disclosure provides a stretchable display substrate and a manufacturing method. The stretchable display substrate includes: a base substrate, a plurality of opening patterns being distributed on the base substrate, a plurality of bridges being formed between adjacent ones of at least a part of opening patterns in the plurality of opening patterns to define islands; a plurality of display units, at least one display unit being arranged on each island; a plurality of wiring units each coupled between the display units on the islands and arranged on the bridge; and a thin film encapsulation layer including a first encapsulation portion covering a side of each display unit away from the base substrate and a second encapsulation portion at least covering a side of each display unit adjacent to the opening pattern. Each of at least a part of opening patterns has different opening sizes at a side of the base substrate adjacent to the display unit and a side of the base substrate away from the display unit, and the opening pattern has at least one step-like structure at a side adjacent to the island. According to the present disclosure, it is able to improve the reliability of a display element.