Stretchable Display Substrate Grooves to Contain Covering Layers
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Solution Overview
Problem
Existing stretchable display devices face issues with the overflow of covering layers on display elements, leading to adhesion to the support plate and reduced manufacturing yield.
Innovation Solution
A patterned insulating structure with device and circuit portions, featuring grooves that surround display elements and conductive wires, prevents covering layers from overflowing by limiting their spread, enhancing scalability and manufacturing yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the covering layer is applied over display elements without grooves, then the display elements are covered and protected, but the covering layer overflows onto circuit portions and adheres to the support plate, reducing manufacturing yield
Solution Approach 1:
The insulating structure is segmented into device portions and circuit portions by grooves. The grooves create physical separation between these portions, preventing the covering layer from spreading from device portions to circuit portions. This segmentation resolves the contradiction by providing both coverage protection and positioning accuracy through structural division.
Solution Approach 2:
The grooves are locally positioned at boundaries between device portions and circuit portions, creating a localized barrier exactly where the covering layer needs to be contained. This local quality approach prevents overflow at critical interfaces without affecting the overall covering layer function, thereby improving both reliability and manufacturing precision.
2Stability of the object's composition
If the covering layer spreads freely during application, then complete coverage is achieved, but the covering layer adheres to the support plate causing defects
Solution Approach 1:
The grooves extract or remove the harmful adhesion effect by creating a physical barrier that prevents the covering layer from contacting the support plate at circuit portions. By taking out the adhesion problem at its source (the interface between covering layer and support plate), the invention maintains covering layer integrity while eliminating the harmful adhesion effect.
Solution Approach 2:
The grooves act as an intermediary barrier between the covering layer and the support plate. This intermediate structure allows the covering layer to maintain its integrity and coverage function while preventing direct contact with the support plate that would cause harmful adhesion. The groove serves as a mediating element that resolves the conflict between coverage and adhesion prevention.
3Ease of manufacture
If the insulating structure has uniform width, then manufacturing is simplified, but the covering layer cannot be effectively contained on device portions
Solution Approach 1:
The insulating structure employs asymmetric width design where device portions have greater width than circuit portions. This asymmetry is strategically implemented to provide sufficient space for covering layer containment on device portions while maintaining ease of manufacture through standardized groove formation. The asymmetric design resolves the contradiction by optimizing the structure for its primary function (covering layer confinement) without significantly complicating the manufacturing process.
Data Source
AI summary
A stretchable substrate metal structure includes a patterned insulating structure, conductive wires, display elements, and covering layers. The patterned insulating structure includes device portions and circuit portions. The surface of each device portion has at least one first groove. At least two of the device portion are separated by a recess. A width of each circuit portion is less than a width of each device portion. Adjacent device portions are connected via corresponding circuit portions. The conductive wires are located in the circuit portions. The display elements are located on the device portions. The at least one first groove of each device portion at least partially surrounds a corresponding display element. Each covering layer is located on a corresponding device portion and covers the corresponding display element.