Display Panel Laser Release Layers for Damage-Free Separation

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Solution Overview

Problem

During the manufacturing of display panels, the panel substrate often gets damaged or transformed while being separated from the carrier substrate, which hampers the expansion of display areas and addition of functions in display apparatuses.

Innovation Solution

A method involving the sequential formation of a first layer and a second layer on a carrier substrate, where the first layer has higher absorbance than the second layer, and a laser beam is used to detach the panel substrate by transferring energy absorbed by the first layer to the first base layer, reducing bonding forces and preventing damage during separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the panel substrate is separated directly from the carrier substrate, then the manufacturing process is simple, but the panel substrate gets damaged or transformed

Engineering Contradiction:

Improvepanel substrate integrityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces a first layer and a second layer as intermediary layers between the panel substrate and the carrier substrate. The first layer has higher absorbance than the second layer, creating a gradient structure that facilitates controlled separation. During laser irradiation, the first layer absorbs more energy and transfers it to the second layer, enabling clean detachment of the panel substrate without damage, thus resolving the contradiction between maintaining substrate integrity and keeping the process simple.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the display area is expanded to add various functions, then the functionality increases, but the panel substrate becomes more prone to damage during separation

Engineering Contradiction:

Improvedisplay function integrationVSAvoidpanel substrate integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The gradient absorbance structure formed by the first and second layers acts as a protective intermediary system that scales with display complexity. As display areas expand and integrate more functions, this intermediary layer structure ensures that separation forces are distributed evenly, preventing damage to the larger, more complex panel substrates while maintaining the ability to add various display functions.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If a laser beam is used to detach the panel substrate, then the separation precision increases, but the energy absorption requirements become more complex

Engineering Contradiction:

Improveseparation precisionVSAvoidenergy absorption structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies local quality by creating a spatial gradient in absorbance properties within the intermediary layers. The first layer has higher absorbance than the second layer, which is higher than the panel substrate. This localized variation in absorbance ensures that laser energy is absorbed preferentially in the first layer and transferred controllably to the second layer, achieving precise separation without requiring complex energy management systems.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent utilizes parameter changes by varying the absorbance properties of different layers. The first layer is designed with higher absorbance than the second layer, creating a gradient that controls laser energy distribution. This parameter variation enables precise separation through controlled energy transfer, resolving the contradiction between separation precision and energy structure complexity.

Inventive Principle:

Principle #35Parameter changes

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 effectively prevents damage to the panel substrate during separation, allowing for the expansion of display areas and integration of additional functions without compromising the panel's integrity or transparency.

Implementation Method 1

absorbing, at the first layer, at least a portion of energy of the laser beam, and transferring the energy of the laser beam in which the at least a portion thereof is absorbed, to the first base layer

Methodology Applied

Scientific EffectAbsorbance: Absorption (EM radiation)

Implementation Method 2

irradiating a laser beam to a bottom surface of the carrier substrate

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 3

forming the first layer and the second layer through chemical vapor deposition (CVD) inside the same chamber

Methodology Applied

Scientific EffectChemical vapor deposition: Chemical Vapour Deposition

Data Source

PatentUS11889741B2Display panel and method of manufacturing the same

Publication Date: 2024.01.30 SAMSUNG DISPLAY CO LTD

AI summary

A method of manufacturing a display panel including: sequentially forming a first layer and a second layer on a carrier substrate such that bottom surfaces of the first layer and the second layer face the carrier substrate; forming a panel substrate including a first base layer on a top surface of the second layer such that a bottom surface of the first base layer faces the second layer; forming a display layer on the panel substrate; and separating the panel substrate from the second layer.