US20110052836A1 - Flexible display and method for manufacturing the same - Google Patents

Flexible display and method for manufacturing the same Download PDF

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Publication number
US20110052836A1
US20110052836A1 US12/870,340 US87034010A US2011052836A1 US 20110052836 A1 US20110052836 A1 US 20110052836A1 US 87034010 A US87034010 A US 87034010A US 2011052836 A1 US2011052836 A1 US 2011052836A1
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Prior art keywords
flexible substrate
flexible
oxide
display
film
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Abandoned
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US12/870,340
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English (en)
Inventor
Tae-Woong Kim
Sung-Guk An
Dong-un Jin
Hyung-Sik Kim
Young-Gu Kim
Sang-Joon SEO
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Samsung Display Co Ltd
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Samsung Mobile Display Co Ltd
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Assigned to SAMSUNG MOBILE DISPLAY CO., LTD. reassignment SAMSUNG MOBILE DISPLAY CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: AN, SUNG-GUK, JIN, DONG-UN, KIM, HYUNG-SIK, KIM, TAE-WOONG, KIM, YOUNG-GU, SEO, SANG-JOON
Publication of US20110052836A1 publication Critical patent/US20110052836A1/en
Assigned to SAMSUNG DISPLAY CO., LTD. reassignment SAMSUNG DISPLAY CO., LTD. MERGER (SEE DOCUMENT FOR DETAILS). Assignors: SAMSUNG MOBILE DISPLAY CO., LTD.
Priority to US14/064,630 priority Critical patent/US9623633B2/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/36—Successively applying liquids or other fluent materials, e.g. without intermediate treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/12—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain a coating with specific electrical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/045—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K50/00—Organic light-emitting devices
    • H10K50/80—Constructional details
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
    • H10K71/80—Manufacture or treatment specially adapted for the organic devices covered by this subclass using temporary substrates
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K77/00—Constructional details of devices covered by this subclass and not covered by groups H10K10/80, H10K30/80, H10K50/80 or H10K59/80
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K77/00—Constructional details of devices covered by this subclass and not covered by groups H10K10/80, H10K30/80, H10K50/80 or H10K59/80
    • H10K77/10—Substrates, e.g. flexible substrates
    • H10K77/111—Flexible substrates
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K85/00—Organic materials used in the body or electrodes of devices covered by this subclass
    • H10K85/60—Organic compounds having low molecular weight
    • H10K85/615—Polycyclic condensed aromatic hydrocarbons, e.g. anthracene
    • H10K85/621—Aromatic anhydride or imide compounds, e.g. perylene tetra-carboxylic dianhydride or perylene tetracarboxylic di-imide
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K2323/00—Functional layers of liquid crystal optical display excluding electroactive liquid crystal layer characterised by chemical composition
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/06—Polymers
    • H01L2924/07—Polyamine or polyimide
    • H01L2924/07025—Polyimide
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K2102/00—Constructional details relating to the organic devices covered by this subclass
    • H10K2102/301—Details of OLEDs
    • H10K2102/311—Flexible OLED
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K50/00—Organic light-emitting devices
    • H10K50/80—Constructional details
    • H10K50/84—Passivation; Containers; Encapsulations
    • H10K50/844—Encapsulations
    • H10K50/8445—Encapsulations multilayered coatings having a repetitive structure, e.g. having multiple organic-inorganic bilayers
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
    • H10K59/10—OLED displays
    • H10K59/12—Active-matrix OLED [AMOLED] displays
    • H10K59/1201—Manufacture or treatment
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
    • H10K59/80—Constructional details
    • H10K59/87—Passivation; Containers; Encapsulations
    • H10K59/873—Encapsulations
    • H10K59/8731—Encapsulations multilayered coatings having a repetitive structure, e.g. having multiple organic-inorganic bilayers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y02E10/549—Organic PV cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/11—Methods of delaminating, per se; i.e., separating at bonding face
    • Y10T156/1153—Temperature change for delamination [e.g., heating during delaminating, etc.]
    • Y10T156/1158—Electromagnetic radiation applied to work for delamination [e.g., microwave, uv, ir, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/263—Coating layer not in excess of 5 mils thick or equivalent
    • Y10T428/264—Up to 3 mils
    • Y10T428/265—1 mil or less
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/266—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension of base or substrate
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31721—Of polyimide

Definitions

  • the embodiments relate to a flexible display and a method for manufacturing the same. More particularly, the embodiments relate to a flexible display which can be stably formed and a method for manufacturing the same.
  • a flexible display includes a display element formed on a flexible substrate.
  • Different types of display elements may be used in a flexible display, including an organic light emitting diode display device, a liquid crystal display device, and an electrophoretic display (EPD) device, etc.
  • These types of display elements commonly include thin film transistors. Accordingly, in order to form a flexible display, the flexible substrate undergoes a number of thin film processes to form thin film transistors.
  • the flexible substrate generally has a relatively thin thickness of several tens of micrometers, it was difficult to perform a number of thin film processes separately on the flexible substrate.
  • a method in which a flexible substrate is firstly formed on a glass substrate, a display element is formed on the flexible substrate adhered to the glass substrate, and then the flexible substrate and the glass substrate are separated from each other is used to perform thin film processes.
  • a flexible substrate made of plastic material generally has a coefficient of thermal expansion (CTE) that is different from the CTE of the glass substrate. If the adhesion force between the flexible substrate and the glass substrate is weak, then the flexible substrate may peel off and away from the glass substrate or be partly removed and bent during a high-temperature process. This may cause a fatal defect in the manufacturing process of a flexible display.
  • CTE coefficient of thermal expansion
  • Embodiments are therefore directed to a flexible display, which can be stably formed, and a method for manufacturing the same, which substantially overcome one or more of the problems due to the limitations and disadvantages of the related art.
  • a flexible display comprising a flexible substrate made of plastic material, a display element on a first surface of the flexible substrate, and a surface residual film containing at least one of a metal material or a metal oxide material, the surface residual film being bonded to at least a part of a second surface of the flexible substrate, the second surface of the flexible substrate being opposed to the first surface.
  • the plastic material may include a functional group of —CONH—.
  • the flexible substrate may be formed from a material containing a polyimide.
  • the flexible substrate may have a thickness ranging from 5 ⁇ m to 200 ⁇ m.
  • the flexible substrate may have a coefficient of thermal expansion ranging from 3 ppm/° C. to 10 ppm/° C.
  • the surface residual film may contain a material bonded to the functional group of —CONH—.
  • the metal material may be bonded to the functional group of —CONH—, and the metal material may include at least one of aluminum, gallium, indium, titanium, molybdenum, and zinc.
  • the metal oxide material may be bonded to the functional group of —CONH—, and the metal oxide material may include at least one of aluminum oxide, gallium oxide, zinc oxide, titanium oxide, indium oxide, indium tin oxide, indium zinc oxide, and gallium indium zinc oxide.
  • the display element may include a thin film transistor.
  • the display element may be an organic light emitting diode display device, a liquid crystal display device, or an electrophoretic display device.
  • the surface residual film may have a thickness ranging from 0.1 nm to 1000 nm.
  • the plastic material may include a functional group of —CONH—.
  • the flexible substrate may be formed from material containing polyimide.
  • the flexible substrate may be formed by a slit coating method or a screen printing method.
  • the flexible substrate has a thickness ranging from 5 ⁇ m to 200 ⁇ m.
  • the flexible substrate may have the same coefficient of thermal expansion as the glass substrate.
  • the flexible substrate may have a coefficient of thermal expansion of less than 10 ppm/° C.
  • the adhesive material film may contain material capable of being bonded to the functional group of —CONH—.
  • the metal material may be bonded to the functional group of —CONH—, and the metal material may include at least one of aluminum, gallium, indium, titanium, molybdenum, and zinc.
  • the metal oxide material may be bonded to the functional group of —CONH—, and the metal oxide material may include at least one of aluminum oxide, gallium oxide, zinc oxide, titanium oxide, indium oxide, indium tin oxide, indium zinc oxide, and gallium indium zinc oxide.
  • the adhesive material film may be formed by atomic layer deposition.
  • the adhesive material film may have a thickness ranging from 0.1 nm to 1000 nm.
  • the method may further comprise separating the flexible substrate and the glass substrate from each other.
  • the flexible substrate and the adhesive material film may be separated from each other by radiation of laser light.
  • the adhesive material film and the glass substrate may be separated from each other by radiation of laser light.
  • the method may further comprise forming a display element on the flexible substrate.
  • the display element may include a thin film transistor.
  • the display element may be any one of an organic light emitting diode display device, a liquid crystal display device, and an electrophoretic display device.
  • the flexible display may effectively suppress occurrence of a defect.
  • the method for manufacturing a flexible display according to embodiments can stably manufacture the above-described flexible display by effectively improving bonding force between the flexible substrate and the glass substrate.
  • FIG. 1 illustrates a cross-sectional view of a flexible display according to an exemplary embodiment
  • FIG. 2 illustrates an enlarged layout view of pixels in the flexible display illustrated in FIG. 1 ;
  • FIG. 3 illustrates a cross-sectional view of a pixel along line illustrated in FIG. 2 ;
  • FIGS. 4-7 illustrate cross-sectional views of the flexible display illustrated in FIG. 1 in sequential manufacturing processes.
  • a flexible display 101 may include a flexible substrate 111 , a display element 110 formed on a first surface of the flexible substrate 111 , and a surface residual film 119 bonded to at least a part of a second surface of the flexible substrate 111 .
  • the second surface of the flexible substrate 111 refers to the surface on the other side or opposite side of the flexible substrate relative to the first surface on which the display element 110 is formed.
  • the flexible substrate 111 may be made of plastic material.
  • the flexible substrate 111 may be made of plastic material containing a functional group of —CONH—.
  • the plastic material may be a polyimide containing the functional group of —CONH—.
  • Polyimides exhibit excellent heat resistance characteristics, and since the flexible display 101 undergoes a high-temperature process, polyimides are highly suitable as a raw material in making the flexible substrate 111 .
  • the flexible substrate 111 may have a thickness ranging from 5 ⁇ m to 200 ⁇ m. If the flexible substrate 111 has a thickness of less than 5 ⁇ m, it may be difficult for the flexible substrate 111 to stably support the display element 110 . Moreover, it may be difficult to form the flexible substrate 111 to have a thickness less than 5 ⁇ m. On the other hand, if the flexible substrate 111 has a thickness greater than 200 ⁇ m, the overall thickness of the flexible display device 101 may be too large, and its flexibility characteristics may be deteriorated.
  • the flexible substrate 111 may be formed to have a CTE ranging from 3 ppm/° C. to 10 ppm/° C. If the CTE of the flexible substrate 111 is less than 3 ppm/° C. or greater than 10 ppm/° C., a difference in a CTE between a glass substrate 900 (shown in FIGS. 4 to 7 ) and the flexible substrate 111 may be too large. It is important that the flexible substrate 111 and the glass substrate 900 be stably bonded to each other. However, because of such a large difference in CTE between the flexible substrate 111 and the glass substrate 900 , the flexible substrate 111 may peel off and away from the glass substrate 900 during a high-temperature process, and a fatal defect may be caused.
  • a surface residual film 119 may be bonded to the functional group of —CONH— contained in the flexible substrate 111 .
  • the surface residual film 119 may contain at least one of a metal material or a metal oxide material. That is, the at least one metal material or metal oxide material contained in the surface residual film 119 may be bonded to the functional group of —CONH— contained in the flexible substrate 111 .
  • the metal material may include at least one of aluminum (Al), gallium (Ga), indium (In), titanium (Ti), molybdenum (Mo), and zinc (Zn).
  • the metal oxide material may include at least one of aluminum oxide, gallium oxide, zinc oxide, titanium oxide, indium oxide, indium tin oxide (ITO), indium zinc oxide (IZO), and gallium indium zinc oxide (GIZO).
  • the at least one metal material or metal oxide material contained in the surface residual film 119 may serve to improve bonding force between the flexible substrate 111 and the glass substrate 900 in the manufacturing process of the flexible display 101 . That is, the at least one metal material or metal oxide material contained in the surface residual film 119 may be firmly bonded to the flexible substrate 111 . Such firm bonding may effectively suppress or prevent the flexible substrate 111 from peeling off or away from the glass substrate 900 .
  • the flexible substrate 111 and the glass substrate 900 may be separated from each other. At this point, at least a part of the metal material or metal oxide material contained in the surface residual film 119 between the flexible substrate 111 and the glass substrate 900 may be bonded to both of the flexible substrate 111 and the glass substrate 900 . Accordingly, this part of the metal material or metal oxide material contained in the surface residual film 119 may remain between the flexible substrate 111 and the glass substrate 900 .
  • the display element 110 may be any one of an organic light emitting diode display device, a liquid crystal display device, and an EPD device. These display elements commonly include thin film transistors (TFTs). Thus, in order to manufacture the flexible display 101 , a number of thin film processes have to be carried out.
  • TFTs thin film transistors
  • FIG. 1 illustrates a flexible display 101 that uses an organic light emitting diode display device as the display element 110 .
  • embodiments are not limited to this embodiment.
  • the overall configuration of the flexible display 101 will be described in detail by referring to the flexible display 101 using an organic light emitting diode display device as the display element 110 .
  • the display element 110 may include an organic light emitting diode 70 and a driving circuit DC.
  • the driving circuit DC may include TFTs 10 and 20 (shown in FIG. 2 ).
  • the driving circuit DC may be configured to drive the organic light emitting diode 70 . That is, the organic light emitting diode 70 may emit light in response to a driving signal transmitted from the driving circuit DC to display an image.
  • FIGS. 2 and 3 An exemplary configuration of the driving circuit DC and the organic light emitting diode 70 are illustrated in FIGS. 2 and 3 . However, embodiments are not limited to the configurations illustrated in FIGS. 2 and 3 . Various configurations of the driving circuit DC and the organic light emitting diode 70 may be formed, and modifications to these configurations are within the purview of those of ordinary skill in the art.
  • FIG. 2 illustrates a layout view of pixels in the flexible display.
  • FIG. 3 illustrates a cross-sectional view of a pixel along line shown in FIG. 2 .
  • FIGS. 2 and 3 illustrate an active matrix (AM)-type organic light emitting diode display 101 having a 2Tr-1Cap structure in which each pixel includes two TFTs 10 and 20 and one capacitor 80 .
  • the flexible display 101 may be configured so that each pixel includes three or more TFTs and two or more capacitors. Also, the flexible display 101 may have various configurations by forming additional wiring.
  • a pixel refers to the smallest unit that is configured to display an image, and is disposed in each pixel area.
  • the flexible display 101 displays an image through a plurality of pixels.
  • each pixel of the display element 110 may include a switching TFT 10 , a driving TFT 20 , a capacitor 80 , and an organic light emitting diode 70 .
  • a component including the switching TFT 10 , the driving TFT 20 , and the capacitor 80 is referred to as the driving circuit DC.
  • the display element 110 may further include a gate line 151 arranged along one direction, a data line 171 crossing the gate line 151 , and a common power line 172 .
  • the data line 171 is insulated from the gate line 151 .
  • One pixel may be defined by the gate line 151 , the data line 171 , and the common line 172 .
  • embodiments are not limited to this embodiment.
  • the organic light emitting diode 70 may include a first electrode 710 serving as an anode, a second electrode 730 serving as a cathode, and an organic emission layer 720 disposed between the first electrode 710 and the second electrode 730 .
  • the first electrode 710 may be a cathode electrode
  • the second electrode 730 may be an anode electrode.
  • the flexible display 101 may be one of front, rear, and dual display types. If the flexible display 101 is of a front display type, the first electrode 710 may be formed from a reflective layer, and the second electrode 730 may be formed from a semi-transmissive layer. On the other hand, if the flexible display 101 is of a rear display type, the first electrode 710 may be formed from a semi-transmissive layer, and the second electrode 730 may be formed from a reflective layer. If the flexible display 101 is of a dual display type, the first electrode 710 and the second electrode 730 may be formed from a transparent layer or a semi-transmissive layer.
  • the reflective layer and the semi-transmissive layer may be made of at least one metal of magnesium (Mg), silver (Ag), gold (Au), calcium (Ca), lithium (Li), chromium (Cr), and aluminum, or an alloy thereof. It may be determined whether the first electrode 710 and the second electrode 730 are formed from the reflective layer or the semi-transmissive layer according to the thickness.
  • the semi-transmissive layer has a thickness of less than 200 nm. As the semi-transmissive layer becomes thinner, the level of transmittance of light through the semi-transmissive layer becomes higher. As the semi-transmissive layer becomes thicker, the level of transmittance of light through the semi-transmissive layer becomes lower.
  • the transparent layer may be made of indium tin oxide, indium zinc oxide, zinc oxide (ZnO), or indium oxide (In 2 O 3 ).
  • the organic emission layer 720 may be formed from multiple layers including one or more of an emission layer, a hole injection layer (HIL), a hole transport layer (HTL), an electron transport layer (ETL), and an electron injection layer (EIL). If the organic emission layer 720 includes all of these layers, the hole injection layer may be disposed on the first electrode 710 serving as an anode, and then the hole transport layer, the emission layer, the electron transport layer, and the electron injection layer may be sequentially stacked on the hole injection layer. Further, the organic emission layer 720 may further include another layer, if necessary.
  • HIL hole injection layer
  • HTL hole transport layer
  • ETL electron transport layer
  • EIL electron injection layer
  • the organic light emitting diode 70 may have holes and electrons injected into the organic emission layer 720 through the first electrode 710 and the second electrode 730 , respectively. When excitons formed by recombination of the injected holes and electrons drop from an excited state to a ground state, the organic light emitting diode 70 may emit light.
  • the capacitor 80 may include a pair of capacitor plates 158 and 178 between which insulating layer 160 is interposed as an interlayer.
  • the insulating layer 160 is made of a dielectric material. Storage capacity is determined by electric charges stored in the capacitor 80 and a voltage potential difference between the capacitor plates 158 and 178 .
  • the switching TFT 10 may include a switching semiconductor layer 131 , a switching gate electrode 152 , a switching source electrode 173 , and a switching drain electrode 174 .
  • the driving TFT 20 may include a driving semiconductor layer 132 , a driving gate electrode 155 , a driving source electrode 176 , and a drain electrode 177 .
  • the switching TFT 10 may be used as a switching element to select a pixel to emit light.
  • the switching gate electrode 152 is connected to the gate line 151 .
  • the switching source electrode 173 is connected to the data line 171 .
  • the switching drain electrode 174 may be spaced apart from the switching source electrode 173 and connected to one of the capacitor plates 158 .
  • the driving TFT 20 may apply driving power to the pixel electrode 710 to emit light from the organic emission layer 720 of the organic light emitting diode 70 in a selected pixel.
  • the driving gate electrode 155 may be connected to the capacitor plate 158 connected to the switching drain electrode 174 .
  • the driving source electrode 176 and the other capacitor plate 178 may be connected to the common power line 172 .
  • the driving drain electrode 177 may be connected to the pixel electrode 710 of the organic light emitting diode 70 through a contact hole.
  • the switching TFT 10 may be driven by a gate voltage applied to the gate line 151 , and supply a data voltage applied to the data line 171 to the driving TFT 20 .
  • a common voltage is supplied from the common power line 172 to the driving TFT 20 .
  • a data voltage is supplied from the switching TFT 10 .
  • a voltage corresponding to a difference between the common voltage and the data voltage may be stored in the capacitor 80 .
  • a current corresponding to the voltage stored in the capacitor 80 may flow into the organic light emitting diode 70 through the driving TFT 20 to make the organic light emitting diode 70 emit light.
  • the flexible display 101 may further include a thin film encapsulation layer 210 formed on the flexible substrate 111 .
  • the thin film encapsulation layer 210 may cover the display element 110 and a barrier film 120 disposed between the display element 110 and the flexible substrate 111 .
  • the thin film encapsulation layer 210 may include at least one of inorganic films 211 , 213 , and 215 , and at least one of organic films 212 and 214 .
  • the inorganic films 211 , 213 , and 215 and the organic films 212 and 214 may be alternately stacked.
  • the inorganic film 211 may be disposed in the lowermost portion. That is, the inorganic film 211 may be disposed closest to the organic light emitting diode 70 .
  • FIG. 4 illustrates that the thin film encapsulation layer 210 includes three inorganic films 211 , 213 , and 215 and two organic films 212 and 214 .
  • embodiments are not limited to this embodiment.
  • the inorganic films 211 , 213 , and 215 may be formed from at least one inorganic material of Al 2 O 3 , TiO 2 , ZrO, SiO 2 , AlON, AlN, SiON, Si 3 N 4 , ZnO, and Ta 2 O 5 .
  • the inorganic films 211 , 213 , and 215 may be formed by chemical vapor deposition or atomic layer deposition. Of these methods, the atomic layer deposition may make it possible to grow and produce the aforementioned inorganic materials at a temperature of less than 100° C. so as to prevent damage of the organic light emitting diode 70 .
  • the inorganic films 211 , 213 , and 215 formed by the atomic layer deposition may effectively suppress permeation of moisture or oxygen because the thin films have high densities.
  • embodiments are not limited to this embodiment.
  • the inorganic films 211 , 213 , and 215 may be formed by various methods that are well known to those of ordinary skill in the art.
  • the organic films 212 and 214 may be made of polymer-based material.
  • the polymer-based material may be acrylic resin, epoxy resin, polyimide, polyethylene, etc.
  • the organic films 212 and 214 may be formed by a thermal deposition process. To form the organic films 212 and 214 , the thermal deposition process may be carried out in a temperature range in which the organic light emitting diode 70 may not be damaged. However, embodiments are not limited to this embodiment.
  • the organic films 212 and 214 may be formed by various methods that are well known to those of ordinary skill in the art.
  • the inorganic films 211 , 213 , and 215 having high thin film densities may suppress permeation mainly of moisture or oxygen.
  • the inorganic films 211 , 213 , and 215 may prevent most of moisture and oxygen from permeating into the organic light emitting diode 70 .
  • Moisture and oxygen passing through the inorganic films 211 , 213 , and 215 may be blocked by the organic films 212 and 214 .
  • the organic films 212 and 214 may have a relatively low ability of preventing moisture permeation compared to the inorganic films 211 , 213 , and 215 .
  • the organic films 212 and 214 also serve as a buffer layer for reducing stress between the layers caused by the bending of the organic light emitting display 101 between the inorganic films 211 , 213 , and 215 and the inorganic films 211 , 213 , and 215 , as well as serving to suppress moisture permeation.
  • the inorganic films 211 , 213 , and 215 are consecutively formed directly on the inorganic films 211 , 213 , and 215 without the organic films 212 and 214 interposed therebetween, when the organic light emitting display 101 is bent, stress is generated between the inorganic films 211 , 213 , and 215 and the inorganic films 211 , 213 , and 215 . This stress may cause damages to the inorganic films 211 , 213 , and 215 . Consequently, the function of the thin film encapsulation layer 210 of preventing moisture permeation may be significantly degraded. In this way, the organic films 212 and 214 may serve as buffer layers as well as serving to suppress moisture permeation.
  • the thin film encapsulation layer 210 may stably prevent permeation of moisture or oxygen. Also, because the organic films 212 and 214 have planarization characteristics, the uppermost surface of the thin film encapsulation layer 210 may be planarized.
  • a thin film encapsulation layer having a thickness of less than 10 ⁇ m may be formed.
  • the overall thickness of the flexible display 101 may be very small.
  • flexibility of the flexible display 101 may be maximized by using the thin film encapsulation layer 210 .
  • the barrier film 120 may be formed from at least one of various inorganic films and organic films.
  • the formed thin film encapsulation layer 210 and barrier film 120 may preferably have a water vapor transmission rate (WWTR) of less than 10 ⁇ 6 g/m 2 /day in order to prevent unnecessary elements from permeating into the organic light emitting diode 70 .
  • the unnecessary elements include moisture permeated into the organic light emitting diode 70 because such moisture may shorten a life span of the organic light emitting diode 70 .
  • the flexible display 101 may effectively suppress generation of a defect.
  • a glass substrate 900 may be prepared, and then an adhesive material film 950 may be formed on the glass substrate 900 .
  • the adhesive material film 950 may have the same constituents as the surface residual film 109 of the flexible display 101 illustrated in FIG. 1 . That is, the adhesive material film 950 may be made of at least one of a metal material or a metal oxide material.
  • the adhesive material film 950 may contain a material that may be bonded to the functional group of —CONH—. Specifically, the adhesive material film 950 may contain at least one metal material including at least one of aluminum, gallium, indium, titanium, molybdenum or zinc. The adhesive material film 950 may contain at least one metal oxide material including at least one of aluminum oxide, gallium oxide, zinc oxide, titanium oxide, indium oxide, indium tin oxide, indium zinc oxide, and gallium indium zinc oxide.
  • the adhesive material film 950 may be formed by sputtering, chemical vapor deposition (CVD), or atomic layer deposition.
  • the atomic layer deposition may be appropriate because the adhesive film material 950 may be formed uniformly and clearly without particles.
  • the adhesive material film 950 may be formed to be not only uniform but also relatively thin.
  • a deposition speed of the atomic layer deposition is very low, i.e., approximately 0.5 ⁇ to 2 ⁇ per cycle. Taking these characteristics of the atomic layer deposition into account, the adhesive material film 950 may be formed to have a thickness t 1 ranging from 0.1 nm to 1000 nm.
  • the adhesive material film 950 may be formed to be thick enough to cover the surface of the glass substrate 900 for surface treatment of the glass substrate 900 . Thus, if the adhesive material film 900 is too thick, the overall production efficiency of the flexible display 101 may be deteriorated due to a relatively low deposition speed of the atomic layer deposition. To this end, the adhesive material film 950 may be preferably formed to have a thickness t 1 of less than 1000 nm.
  • a flexible substrate 111 may be formed on the adhesive material film 111 .
  • the flexible substrate 111 may be made of plastic material containing the functional group of —CONH—.
  • the flexible substrate 111 may be formed of polyimide containing the functional group of —CONH—. Polyimide is particularly excellent in heat resistance. Since the flexible display 101 has to undergo a number of high-temperature processes, polyimide may be suitable as a raw material of the flexible substrate 111 of the flexible display 101 .
  • the flexible substrate 111 may be formed by either a slit coating method or a screen printing method. That is, the polyimide may be coated on the adhesive material film 950 by the slit coating method or the screen printing method, and the flexible substrate 111 may be formed accordingly. At this point, the functional group of —CONH— contained in the flexible substrate 111 may be firmly bonded to the adhesive material film 950 . In general, metal material or metal oxide material has very good adhesion force to the glass substrate 900 . Accordingly, the flexible substrate 111 and the glass substrate 900 may be stably adhered to each other by the adhesive material film 950 .
  • the flexible substrate 111 may be formed so as to have a thickness t 2 ranging from 5 ⁇ m to 200 ⁇ m due to a manufacturing environment or the flexible characteristics.
  • the flexible substrate 111 having a thickness t 2 of approximately 10 ⁇ m may be formed from polyimide by the slit coating method, for example.
  • the flexible substrate 111 having a thickness t 2 ranging from approximately 10 ⁇ m to 70 ⁇ m may be formed from polyimide by the screen printing method.
  • the flexible substrate 111 may be formed so as to have the same CTE as the glass substrate 900 or a CTE of less than 10 ppm/° C.
  • the glass substrate 900 has a CTE of approximately 4 ppm/° C.
  • the flexible substrate 111 and the glass substrate should be stably bonded to each other. If a difference in a CTE between the flexible substrate 111 and the glass substrate 900 becomes too large, the flexible substrate 111 may be peeled off from the glass substrate 900 during a high-temperature process. This may cause a defect in the manufacturing process.
  • the flexible substrate 111 and the glass substrate 900 may be effectively bonded to each other, and thus enable stable manufacture of the flexible display 101 .
  • a barrier film 120 may be formed on the flexible substrate 111 , and a display element 110 may be formed on the barrier film 120 . Then, a thin film encapsulation layer 210 for covering the display element 110 may be formed on the flexible substrate 111 .
  • the barrier film 120 and the thin film encapsulation layer 210 may be omitted if necessary according to the type of the display element 110 .
  • their configuration on the flexible substrate 111 may vary according to the type of the display element 110 .
  • FIG. 6 illustrates that the display element 110 is an organic light emitting element.
  • the display element may be either a liquid crystal display device or an EPD device if a display device is not an organic light emitting diode display device.
  • these display elements 110 commonly include TFTs.
  • the flexible substrate 111 and the glass substrate 900 may undergo a number of high-temperature processes, while being bonded to each other.
  • a laser light L may be irradiated to separate the flexible substrate 111 and the glass substrate 900 from each other. Specifically, by radiation of laser light, the flexible substrate 111 and the adhesive material film 950 may be separated from each other, or the adhesive material film 950 and the glass substrate 900 may be separated from each other.
  • the flexible substrate 111 and the glass substrate 900 may be separated, and the flexible display 101 may be completed.
  • the flexible display 101 manufactured according to the exemplary embodiment as illustrated in FIG. 1 , at least part of the metal material or metal oxide material bonded to the flexible substrate 111 may remain bonded to the flexible substrate 111 .
  • the flexible display 101 may be stably manufactured by effectively improving the bonding force between the flexible substrate 111 and the glass substrate 900 .

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Ceramic Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Materials Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Optics & Photonics (AREA)
  • Electroluminescent Light Sources (AREA)
  • Devices For Indicating Variable Information By Combining Individual Elements (AREA)
  • Liquid Crystal (AREA)
  • Electrochromic Elements, Electrophoresis, Or Variable Reflection Or Absorption Elements (AREA)
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US9623633B2 (en) 2017-04-18

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