Display Panel Fabrication Using Supporting Substrates to Prevent Warping
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Solution Overview
Problem
The integration of touch input functionality into display panels often damages pre-formed color filters and requires substrates thicker than 0.4 mm to prevent breaking, limiting the ability to create thin, high-transmission display panels and leading to issues with substrate warping and misalignment during fabrication.
Innovation Solution
A method involving the use of supporting substrates with adhesive layers to buffer and protect the main substrate during fabrication, allowing for precise device formation and assembly of display panels with substrates as thin as 0.05 mm to 0.2 mm, thereby preventing damage and warping, and enabling the creation of thin, high-transmission display panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If color filters are formed on the substrate surface in advance and touch devices are formed on another surface, then touch input function is integrated into the display panel, but the color filters are damaged during touch device formation leading to poor yield
Solution Approach 1:
The substrate processing is divided into separate stages: color filter formation on the first substrate, then separation of the first substrate from the supporting substrate, followed by touch device formation on a different substrate. This segmentation prevents damage to color filters during touch device fabrication while still achieving integrated touch display functionality.
Solution Approach 2:
Color filters are formed on the first substrate before the substrate is separated from the supporting substrate. This preliminary formation of color filters on a supported substrate ensures they are protected during subsequent processing steps, and the supporting substrate is removed only after the color filters are securely formed.
2Length of stationary object
If substrate thickness is reduced to meet thin type display panel demand, then overall thickness is reduced, but the substrate breaks during fabrication
Solution Approach 1:
A supporting substrate is provided beforehand and bonded to the first substrate using a first adhesive layer. This supporting substrate acts as a cushion that prevents the thin first substrate from breaking during fabrication processes, enabling the use of substrates thinner than 0.4mm without compromising structural integrity.
Solution Approach 2:
The supporting substrate serves as an intermediary that provides mechanical support to the thin first substrate during fabrication. The adhesive layer acts as a bonding intermediary that securely attaches the thin substrate to the supporting substrate, enabling processing of ultra-thin substrates that would otherwise be too fragile.
3Adaptability or versatility
If substrate is warped during the double-side fabricating process, then the substrate breaks or mal-alignment occurs, but double-side fabrication is necessary for on-cell touch display
Solution Approach 1:
The double-side fabrication process is segmented into separate operations on separate substrates. Color filters are formed on the first substrate, which is then separated from the supporting substrate. Touch devices are formed on a different substrate. Finally, the first and second substrates are assembled together. This segmentation eliminates warping issues during fabrication while maintaining the ability to create on-cell touch displays with precise alignment.
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 allows for the fabrication of thin, high-transmission display panels with improved yield and precision, preventing substrate damage and warping, and enabling the use of thinner substrates while maintaining the necessary structural integrity and touch input functionality.
Implementation Method 1
The second surface of the first substrate is bonded to a first supporting substrate with a first adhesive layer
Data Source
AI summary
A method for fabricating a display panel includes the following steps. A surface of a first substrate is adhered to a first supporting substrate with a first adhesive layer. First devices are formed on the other surface of the first substrate. The other surface of the first substrate is adhered to a second supporting substrate with a second adhesive layer. The first adhesive layer and supporting substrate are separated from the first substrate. Second devices are formed on the surface of the first substrate. A second substrate is adhered to a third supporting substrate with a third adhesive layer. The first substrate and the second substrate are assembled, and a display medium layer is interposed between the first substrate and the second substrate. The second adhesive layer and supporting substrate are separated from the first substrate, and the third adhesive layer and supporting substrate are separated from the second substrate.