TFT Array Panel Stress Elimination Layer Design
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Solution Overview
Problem
Conventional flexible displays face warpage and bending issues due to differing expansion coefficients between glass and flexible baseplates, complicating the manufacturing process.
Innovation Solution
A TFT array panel with a flexible baseplate and a buffer layer featuring a stress-elimination portion, such as cave or protrusion arrays, formed through photo-mask or etching processes, to reduce stress on the flexible baseplate, and a shielding layer to support the display-element layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flexible displays are fixed on glass baseplates to enable manufacturing processes, then the manufacturing process can be performed, but warpage and bending occur due to different expansion coefficients
Solution Approach 1:
The stress-elimination layer is divided into multiple independent through-holes arranged in arrays, which segment the stress distribution across the substrate. This segmentation allows the flexible baseplate to accommodate thermal expansion differences without causing overall warpage, while still providing a stable platform for manufacturing processes.
Solution Approach 2:
The stress-elimination layer introduces localized voids (through-holes) at specific positions rather than uniformly modifying the entire structure. This local modification approach eliminates stress at critical points while maintaining the structural integrity and flatness required for manufacturing processes in other areas.
2Stability of the object's composition
If a stress-elimination layer with through-holes is added to reduce stress, then warpage is reduced, but the device structure becomes more complex
Solution Approach 1:
The stress-elimination layer serves as an intermediary between the flexible baseplate and the display structure. This intermediate layer with through-holes acts as a buffer that decouples the stress transmission, reducing warpage without requiring fundamental changes to the existing display structure or manufacturing processes.
3Adaptability or versatility
If the flexible baseplate is made thinner to improve flexibility, then flexibility increases, but the baseplate cannot withstand manufacturing processes directly
Solution Approach 1:
The patent creates a composite structure by combining the thin flexible baseplate with a stress-elimination layer containing through-holes. This composite design allows the thin baseplate to maintain its flexibility while the stress-elimination layer provides the necessary mechanical support to withstand manufacturing processes such as lithography and etching.
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 solution effectively decreases stress on the flexible baseplate, preventing warpage and enhancing the precision of lithography-position processes by stabilizing the glass substrate used for flexible displays.
Implementation Method 1
A stress-elimination portion is disposed on the buffer layer. The stress-elimination portion is used to eliminate a stress of the flexible baseplate
Data Source
AI summary
The present invention provides a thin-film-transistor (TFT) array panel and manufacturing method of the same. The TFT array panel comprises a flexible baseplate, a buffer layer, and a display-element layer. The buffer layer is disposed on the flexible baseplate, a stress-elimination portion is disposed on the buffer layer, the stress-elimination portion is used to eliminate a stress of the flexible baseplate; the display-element layer is disposed on the buffer layer. The present invention is able to decrease the stress of the flexible baseplate, to prevent too large of a stress of the flexible baseplate.