Thick Wire Embedding in Flexible Display Substrates
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Solution Overview
Problem
The challenge is to manufacture large-screen display devices with high productivity while minimizing voltage reduction due to wiring resistance and addressing the issues of protruding and recessed parts caused by thick wires, which require lengthy and costly processes such as reactive ion etching and vacuum thin film forming.
Innovation Solution
A display device with a flexible wire embedded layer that incorporates a thick wire, ensuring low electrical resistance and reduced planarity issues, achieved by embedding the thick wire to be substantially flush with the layer, allowing for efficient manufacturing with a simple pressing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thick wires are used to reduce electrical resistance, then wiring resistance decreases, but protruding and recessed parts are formed on the substrate surface
Solution Approach 1:
A resin layer is introduced as an intermediary material between the thick wire and the substrate. This resin layer fills the space around the thick wire, embedding it and planarizing the substrate surface. The resin acts as a mediator that accommodates the thick wire's presence while maintaining surface flatness, allowing thick wires to be used for low resistance without creating protruding or recessed parts that would interfere with subsequent manufacturing steps.
2Manufacturing precision
If conventional vacuum processes and reactive ion etching are used to address thick wire issues, then substrate surface planarity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of using expensive and complex vacuum processes or reactive ion etching, the invention employs a simple resin coating process that uses inexpensive materials and equipment. The resin layer is applied through conventional coating methods rather than sophisticated vacuum or plasma processes, dramatically simplifying the manufacturing process while achieving the same planarization effect. This approach replaces high-cost, complex processes with a simple, low-cost alternative.
3Ease of manufacture
If thin wires are used in conventional manufacturing, then manufacturing process is simpler, but electrical resistance increases causing voltage reduction
Solution Approach 1:
The invention changes the thickness parameter of the wire from thin to thick, which fundamentally alters the electrical resistance characteristic. By using thick wires, the cross-sectional area increases, thereby reducing electrical resistance and preventing voltage reduction. The resin embedding process enables this parameter change by solving the surface planarity issue that would otherwise result from using thick wires.
Data Source
AI summary
A flexible display device includes a wire embedded layer that has flexibility and has a first principal surface, a thick wire embedded in the wire embedded layer so as to be substantially flush with the first principal surface of the wire embedded layer, an extraction lower electrode electrically connected to the thick wire and disposed on the first principal surface of the wire embedded layer, an emitting layer disposed on the extraction lower electrode, and an upper electrode disposed on the emitting layer. The flexible display device is suitable for large-screen devices and offers high productivity.