Display Module Reworking via Thermal Adhesive Softening
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Solution Overview
Problem
The existing reworking process for display modules is inefficient due to the risk of damaging non-defective components when applying physical force to separate defective components, leading to a low success rate in replacing defective parts.
Innovation Solution
A reworking apparatus with a temperature control unit that reduces the adhesive properties of the adhesive material, allowing for the use of a separation unit with a separation knife and frame to carefully separate layers of the display module without applying excessive physical force, including a stage to secure the module and a movement unit to precisely control the separation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If physical force is applied to separate defective component from other components, then the defective component can be removed, but the non-defective components may be damaged
Solution Approach 1:
The patent applies temperature control to change the physical state of the adhesive material. By heating to a specific temperature range, the adhesive transitions from a bonded state to a separable state, reducing the force needed for separation and preventing damage to non-defective components.
Solution Approach 2:
The patent replaces the manual mechanical separation process with a thermal field-based separation process. Instead of using mechanical force to separate components, the system uses controlled heating to alter the adhesive properties, allowing for damage-free separation.
2Ease of operation
If temperature is increased to reduce adhesive property, then the separation becomes easier, but excessive heat may damage the display module components
Solution Approach 1:
The patent precisely controls the temperature parameter within a specific range (50°C to 100°C) to achieve the desired adhesive softening effect while staying below the damage threshold of display module components. This controlled parameter change enables easy separation without thermal damage.
Solution Approach 2:
The patent employs a temperature control unit with feedback mechanisms to maintain the temperature within the safe operating range. The system continuously monitors and adjusts the heating to prevent overheating, ensuring components are not damaged while achieving effective separation.
3Device complexity
If manual reworking process is used, then the process is simple, but the success rate is low due to human error and physical damage
Solution Approach 1:
The patent creates a self-regulating system where the temperature control unit automatically maintains the adhesive at the optimal separation temperature. The controlled thermal environment enables the separation process to proceed reliably without requiring high skill levels or manual judgment, reducing human error.
Solution Approach 2:
The patent introduces a temperature control unit as an intermediary between the heating source and the display module. This intermediary device precisely regulates the thermal energy transfer, ensuring uniform and controlled heating that prevents localized overheating and component damage.
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
The apparatus effectively increases the success rate of reworking display modules by reducing damage to non-defective components and ensuring precise separation of layers, enhancing the reliability of the reworking process.
Implementation Method 1
a temperature control unit which controls a temperature in the chamber to reduce an adhesive property of an adhesive material of the display module
Data Source
AI summary
A reworking apparatus for a display module includes a chamber and a temperature control unit. The temperature control unit controls a temperature in the chamber to reduce an adhesive property of an adhesive material of the display module. The adhesive material couples a first layer of the display module to a second layer of the display module. A stage is disposed in the chamber and holds the display module. A separation unit is disposed in the chamber and is inserted in between first and second layers of the display module. A movement unit moves the separation unit.