Acid Window Removal for Display Device Yield
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Solution Overview
Problem
In the manufacturing of display devices, defects in components such as the window lead to decreased yield and cost efficiency, as removing the defective components can damage other components, resulting in their reuse being compromised.
Innovation Solution
A method involving the use of an acid solution to remove the first window from a display device assembly, allowing for the reuse of undamaged components, where the acid solution includes compounds like hydrogen fluoride, ammonium hydrogen fluoride, and sulfuric acid, and the process is controlled to prevent damage to underlying components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the defective window is removed using conventional methods, then the defective component is replaced, but other components may be damaged resulting in decreased yield and cost efficiency
Solution Approach 1:
The patent introduces an acid solution as an intermediary substance to selectively remove the defective window. The acid solution acts as a mediator that targets only the window material (glass or plastic) without affecting other components like the display module, adhesive layers, or protective films, thereby enabling safe replacement and improving manufacturing yield
Solution Approach 2:
The patent employs parameter changes by controlling the concentration, temperature, and exposure time of the acid solution to achieve selective removal of the window. By adjusting these parameters, the process selectively targets the window material while preserving other components, resolving the contradiction between effective defect removal and component protection
2Ease of manufacture
If the defective window is removed using mechanical or thermal methods, then the window is replaced, but the complexity and risk of damaging other components increases
Solution Approach 1:
The patent replaces mechanical removal methods (such as cutting, breaking, or prying) with a chemical dissolution process using acid solution. This substitution eliminates the need for complex mechanical tools and operations, simplifying the manufacturing process and reducing the risk of damaging other components through mechanical stress
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
This method enables the effective replacement of the window without damaging other components, thereby increasing manufacturing yield and reducing costs by allowing the reuse of undamaged parts.
Implementation Method 1
The first window may be removed by providing an acid solution on the first display device assembly
Implementation Method 2
The first protective layer may be removed by applying heat to the first display device assembly
Data Source
AI summary
A method for manufacturing a display device includes providing a first display device assembly comprising a display module, a first window disposed on the display module, a first window adhesive layer disposed between the display module and the first window, and a first protective layer disposed on the first window. The first protective layer is removed. The first window is removed by providing an acid solution on the first display device assembly. A second window is provided that is disposed on the display module after the first window is removed. A second protective layer is provided that is disposed on the second window after the first protective layer is removed.