Two-Stage Detachment of Display Module from Carrier Substrate
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Solution Overview
Problem
The existing methods for detaching a display module from a carrier substrate often result in defects, particularly due to the adhesion forces between the display module and the protective film, which can lead to incomplete detachment and damage during the manufacturing process.
Innovation Solution
A method involving a two-stage detachment process using distinct detaching units, where the first unit directly contacts the display module to detach one area, and the second unit contacts the protective film to detach both the module and the film from the carrier substrate, with varying absorption forces and positioning to minimize defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single detaching unit is used to detach the display module from the carrier substrate, then the detachment process is simple, but detachment defects occur due to adhesion forces between the display module and protective film
Solution Approach 1:
The detachment process is segmented into two distinct stages: first detaching the display module from the carrier substrate, then detaching the protective film from the display module. This segmentation allows each detaching unit to be optimized for its specific task, preventing defects caused by attempting to detach both components simultaneously with a single unit.
Solution Approach 2:
The first detaching unit acts as an intermediary that selectively detaches the display module from the carrier substrate while leaving the protective film attached. This intermediate step enables controlled separation that manages adhesion forces between components, avoiding damage that would occur with direct single-unit detachment of all components.
2Manufacturing precision
If the first detaching unit directly contacts the display module to detach it from the carrier substrate, then the detachment is effective, but the protective film may adhere to the display module causing defects
Solution Approach 1:
The detachment process is divided into two sequential operations: first removing the display module from the carrier substrate while the protective film remains attached, then separately removing the protective film. This segmentation prevents the harmful adhesion effect by timing the film detachment to occur after the module has been successfully detached.
Solution Approach 2:
The first detaching unit performs a preliminary detachment action by removing the display module from the carrier substrate before the protective film detachment occurs. This preliminary action establishes the display module as a separate component, eliminating the carrier substrate as a source of adhesion conflicts.
3Reliability
If the protective film covers the entire display module for protection, then protection is complete, but detachment becomes difficult and defect-prone
Solution Approach 1:
The protective film coverage and detachment process are segmented into two phases: during manufacturing, the film provides complete coverage for protection; during detachment, the process is segmented to first remove the display module with the film still attached, then separately remove the film. This segmentation resolves the contradiction by maintaining full protection during manufacturing while enabling controlled detachment afterward.
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 approach reduces detachment defects by managing adhesion forces and ensuring controlled separation, maintaining the integrity of the display module and protective film during the detachment process.
Implementation Method 1
the first detaching unit may include a first absorption pad, and the second detaching unit may include a second absorption pad, and the first detaching process may be performed by the first absorption pad, and the second detaching process is performed by the second absorption pad
Implementation Method 2
the first detaching unit may include a support and an adhesive tape wound around the support, and in the first detaching process, the second area may adhere to the adhesive tape and be detached from the carrier substrate
Data Source
AI summary
Provided is a method of detaching a display module. The method of detaching the display module includes providing a carrier substrate, forming a display module, which is divided into a first area and a second area, on the carrier substrate, disposing a protective film covering the first area and exposing the second area on the display module, performing a first detaching process of detaching the second area from the carrier substrate by using a first detaching unit, and performing a second detaching process of detaching the protective film and the display module from the carrier substrate by using a second detaching unit.