CN105552225B - 用于制造柔性基板的方法、柔性基板和显示装置 - Google Patents
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Abstract
本发明公开了一种用于制造柔性基板的方法、使用该方法制成的柔性基板和包括所述柔性基板的显示装置。所述方法包括步骤:在玻璃载体上涂布多层膜层,其中所述多层膜层中的至少一对相邻膜层中的每一对相邻膜层以如下方式形成:涂布第一膜层,和在所述第一膜层上涂布第二膜层,使所述第二膜层覆盖所述第一膜层,其中所述第二膜层的面积大于所述第一膜层的面积;和将所形成的膜层结构从所述玻璃载体上剥离,形成柔性基板。
Description
技术领域
本发明涉及柔性基板领域,尤其涉及一种用于制造柔性基板的方法、通过该方法制成的柔性基板和包括该柔性基板的显示装置。
背景技术
与传统的硬质基板相比,能够弯曲的柔性基板以其重量轻、厚度薄、柔软等优点被越来越广泛地应用于薄膜印刷电路板、可弯曲显示面板等领域中。在柔性基板的制造技术中,通常是在玻璃载体上多次涂布聚酰亚胺或聚醚醚酮等材料而形成多层膜层,并且将所形成的多层膜层剥离,从而形成最终的柔性基板。然而,如图1所示,在涂布膜层的过程中,在涂膜的周围会有突起的膜厚不稳定区,而且这个膜厚不稳定区随着膜厚的增高而变大,随着膜层的增多而变高。
发明内容
为了克服或者至少缓解上述缺点,本发明提供一种新颖的用于制造柔性基板的方法。具体地,根据本发明的一方面,提供一种用于制造柔性基板的方法,包括步骤:在玻璃载体上涂布多层膜层,其中所述多层膜层中的至少一对相邻膜层中的每一对相邻膜层以如下方式形成:涂布第一膜层;在所述第一膜层上涂布第二膜层,使所述第二膜层覆盖所述第一膜层,其中所述第二膜层的面积大于所述第一膜层的面积;和将所形成的多层膜层结构从所述玻璃载体上剥离,形成柔性基板。
在根据本发明的用于制造柔性基板的方法中,虽然在第一次涂布中在第一膜层的边缘处形成了厚度不稳定部分,但是通过在第一膜层上涂布第二膜层,使得第二膜层覆盖第一膜层,即第二膜层的面积大于第一膜层,可以使该厚度不稳定部分被随后涂布的第二膜层覆盖而实现平坦化,从而仅仅在第二膜层的边缘处形成厚度不稳定部分。这样,增大了工艺使用区域,消除了双层涂布所带来的可用涂布面积小、膜厚不稳定区域大的问题。
优选地,在所述第一膜层上涂布第二膜层,使所述第二膜层覆盖所述第一膜层的步骤中,所述第一膜层的边缘与所述第二膜层的边缘之间相距5mm或大于5mm。
优选地,在所述第一膜层上涂布第二膜层,使所述第二膜层覆盖所述第一膜层的步骤之前,在所述第一膜层上设置阻隔层,用于阻隔水和/或氧,且在所述玻璃载体上涂布第二膜层,使所述第二膜层覆盖所述第一膜层的步骤之后,所述第二膜层覆盖所述阻隔层。
在一实施例中,通过夹缝挤出式涂布方式涂布所述第一膜层和所述第二膜层。
在一实施例中,所述至少一对相邻膜层包括一对相邻膜层,并且第一膜层被涂布设置在所述玻璃载体上。
在一实施例中,所述第一膜层和所述第二膜层是聚酰亚胺膜层。
根据本发明的另一方面,提供一种通过上述方法制作的柔性基板。优选地,所述第二膜层的厚度至少大于或等于所述第一膜层的厚度的10%。
根据本发明的还一方面,提供一种包括上述柔性基板的显示装置。
附图说明
通过下面结合附图说明本发明的优选实施例,将使本发明的上述及其它目的、特征和优点更加清楚,其中:
图1示意性地示出涂布膜层时涂膜周围的突起的膜厚不稳定区随着膜厚的增高而变大的原理图;和
图2A-2C示意性地示出根据本发明实施例的用于制作柔性基板的方法的一个示例的各个步骤所对应的结构示意图。
在本发明的所有附图中,相同或相似的结构均以相同或相似的附图标记标识。另外,本发明的附图仅为示意目的,并非按比例绘制。
具体实施方式
下面参照附图对本发明的优选实施例进行详细说明,在描述过程中省略了对于本发明来说是不必要的细节和功能,以防止对本发明的理解造成混淆。此外,应该指出的是,本发明中所用的“第一”和“第二”仅仅是为了便于在描述过程中进行区别,而并没有任何限定作用。
如图2A-2C所示,根据本发明实施例的用于制造柔性基板的方法的一个示例包括步骤:在玻璃载体1上涂布第一膜层2;在玻璃载体1上涂布第二膜层4,使第二膜层4覆盖第一膜层2,其中第二膜层4的面积大于第一膜层2的面积;和将所形成的膜层结构从玻璃载体1上剥离,形成柔性基板。
在根据本发明的用于制造柔性基板的方法中,虽然在第一次涂布中在第一膜层的边缘处形成了厚度不稳定部分2a,但是通过在第一膜层上涂布第二膜层,使得第二膜层覆盖第一膜层,即第二膜层的面积大于第一膜层,可以使该厚度不稳定部分2a被随后涂布的第二膜层覆盖而实现平坦化,从而仅仅在第二膜层的边缘处形成厚度不稳定部分4a。这样,增大了工艺使用区域,消除了双层涂布所带来的问题。
在一可选或优选实施例中,在玻璃载体1上涂布第二膜层4,使第二膜层4覆盖第一膜层2的步骤之前,在第一膜层2上设置阻隔层3(例如由能够阻隔水和/或氧的无机材料形成),用于阻隔水和/或氧,且在玻璃载体1上涂布第二膜层4,使第二膜层4覆盖第一膜层2的步骤之后,第二膜层4覆盖阻隔层3。
应该指出的是,本发明不局限于涂布两层膜层,可以涂布多个膜层,只要多个膜层中的至少一对相邻膜层以与上述第一膜层和第二膜层的形成方式相同的方式形成即可。可选地,所述至少一对相邻膜层之间可以设置阻隔层(例如由能够阻隔水和/或氧的无机材料形成),用于阻隔水和/或氧。在上述实例中,所述至少一对相邻膜层包括一对相邻膜层,其中第一膜层被涂布设置在玻璃载体上。
在一实施例中,第一膜层2和第二膜层4是聚酰亚胺膜层。然而,本发明不局限于此。可以使用适于形成柔性基板的任何材料。
此外,在一实施例中,可以通过夹缝挤出式涂布方式涂布第一膜层2和第二膜层4。采用这种方式能够实现面积大、厚度厚的膜层,并且节省材料。而且,由于厚度不稳定区域的问题主要出现在夹缝挤出式涂布方式中,因此,本发明的用于制作柔性基板的方法尤其适用此种涂布方式。此外,阻隔层3可以使用现有的任何适当的方式和材料形成。
在一个优选实施例中,在第一膜层2或玻璃载体1上涂布第二膜层4,使第二膜层4覆盖第一膜层2的步骤中,第一膜层2的边缘与第二膜层4的边缘之间相距5mm或大于5mm,即第一膜层2的边缘与第二膜层4的边缘之间的距离d为大于或等于5mm。应该指出的是,可以通过调整工艺参数等方法,例如修改输入工艺加工软件中的工艺参数,容易地利用现有设备实现上述涂布第二膜层、使第一膜层的边缘与第二膜层的边缘相距一段距离,例如等于或大于5mm的步骤,而不需要额外的设备和工艺。
在一优选实施例中,第二膜层4的厚度至少大于或等于第一膜层2的厚度的10%。这样设置的原因在于,发明人发现:膜层的厚度不稳定区域的厚度突起部分的高度一般是膜层厚度的10%。因此,设置第二膜层的厚度至少大于或等于第一膜层的厚度的10%能够保证第二膜层必然覆盖第一膜层的厚度不稳定区域,实现该处的平坦化。
以上参考具体实施例描述了根据本发明的用于制作柔性基板的方法。本发明还提供一种通过如上所述方法制作的柔性基板和包括所述柔性基板的显示装置。
至此已经结合优选实施例对本发明进行了描述。应该理解,本领域技术人员在不脱离本发明的精神和范围的情况下,可以进行各种其它的改变、替换和添加。因此,本发明的范围不局限于上述特定实施例,而应由所附权利要求所限定。
Claims (6)
1.一种用于制造柔性基板的方法,包括步骤:
在玻璃载体上涂布多层膜层,其中所述多层膜层中的至少一对相邻膜层中的每一对相邻膜层以如下方式形成:
涂布第一膜层;
在所述第一膜层上涂布第二膜层,使所述第二膜层覆盖所述第一膜层,其中所述第二膜层的面积大于所述第一膜层的面积;和
将所形成的多层膜层结构从所述玻璃载体上剥离,形成柔性基板,
其中在第一膜层的涂布中在第一膜层的边缘处形成厚度不稳定部分,并且该厚度不稳定部分被随后涂布的第二膜层覆盖而仅在第二膜层的边缘处形成厚度不稳定部分,
其中通过夹缝挤出式涂布方式涂布所述第一膜层和所述第二膜层,并且
其中第二膜层的平整部分超出第一膜层的边缘。
2.根据权利要求1所述的方法,其中在所述第一膜层上涂布第二膜层,使所述第二膜层覆盖所述第一膜层的步骤中,所述第一膜层的边缘与所述第二膜层的边缘之间相距5mm或大于5mm。
3.根据权利要求1或2所述的方法,还包括:在所述第一膜层上涂布第二膜层,使所述第二膜层覆盖所述第一膜层的步骤之前,在所述第一膜层上设置阻隔层,用于阻隔水和/或氧,且在所述第一膜层上涂布第二膜层,使所述第二膜层覆盖所述第一膜层的步骤之后,所述第二膜层覆盖所述阻隔层。
4.根据权利要求1或2所述的方法,其中所述至少一对相邻膜层包括一对相邻膜层,并且第一膜层被涂布设置在玻璃载体上。
5.根据权利要求4所述的方法,还包括步骤:在所述一对相邻膜层之间设置阻隔层,用于阻隔水和/或氧。
6.根据权利要求1或2所述的方法,其中所述第一膜层和所述第二膜层是聚酰亚胺膜层。
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