Display Window Salt Treatment Crack Removal

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Solution Overview

Problem

Flat panel displays face challenges in achieving both high strength and transmittance, particularly in withstanding external impacts and maintaining image clarity, due to surface cracks that degrade their mechanical and optical properties.

Innovation Solution

A method involving a salt treatment process on a mother substrate to form a silicon-rich layer with a specific silicon content ratio, followed by its removal, which enhances the strength and transmittance of the display window by removing surface cracks and ensuring a smooth surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a conventional glass substrate is used for display windows, then the manufacturing process is simple, but the surface cracks reduce impact resistance and strength

Engineering Contradiction:

Improveimpact resistanceVSAvoidsurface cracks

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by performing salt treatment on the mother substrate before final processing to proactively remove surface cracks. The salt treatment process penetrates into the substrate surface and eliminates crack sources in advance, preventing future strength issues rather than addressing them after they manifest.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces mechanical crack removal methods (such as polishing or grinding) with a chemical salt treatment process. The molten salt chemically interacts with the glass substrate to dissolve and remove cracked regions, providing a more precise and less damaging alternative to mechanical removal methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If the silicon-rich layer is formed deeper to remove all cracks, then impact resistance improves, but transmittance decreases due to surface roughness

Engineering Contradiction:

Improveimpact resistanceVSAvoidtransmittance

Core Design Contradiction:

StrengthVSIllumination intensity

Solution Approach 1:

The patent applies parameter changes by precisely controlling the salt treatment temperature (400-600°C), treatment time (1-24 hours), and silicon content ratio (1.2-1.4) to achieve optimal crack removal while maintaining surface smoothness. By adjusting these parameters, the process removes cracks effectively without creating excessive surface roughness that would reduce transmittance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies local quality by creating a silicon-rich layer with specific properties at the surface region while maintaining the bulk substrate properties. The silicon-rich layer formed at 100-500 nm depth provides crack-free strength enhancement locally without affecting the overall optical properties of the substrate, thus maintaining high transmittance.

Inventive Principle:

Principle #3Local quality

3Illumination intensity

If the silicon-rich layer is completely removed, then transmittance improves, but surface smoothness may be compromised

Engineering Contradiction:

ImprovetransmittanceVSAvoidsurface smoothness

Core Design Contradiction:

Illumination intensityVSShape

Solution Approach 1:

The patent applies partial action by selectively removing the silicon-rich layer rather than completely eliminating it. The layer is removed to the extent necessary to eliminate surface irregularities and improve transmittance, while retaining sufficient silicon enrichment to maintain surface smoothness and the beneficial crack-free structure.

Inventive Principle:

Principle #16Partial or excessive action

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 method results in a display window with improved impact resistance, maintaining high transmittance and surface smoothness, capable of withstanding significant external impacts without breaking and ensuring clear image transmission.

Implementation Method 1

performing a salt treatment on the mother substrate to form a silicon-rich layer in a surface of the mother substrate

Methodology Applied

Scientific EffectSalt treatment:

Implementation Method 2

removing the silicon-rich layer, wherein removing the silicon-rich layer may include cleansing the silicon-rich layer using a basic solution

Methodology Applied

Scientific EffectChemical cleansing:

Data Source

PatentUS10899662B2Display window and manufacturing method thereof

Publication Date: 2021.01.26 SAMSUNG DISPLAY CO LTD

AI summary

According to an exemplary embodiment of the present disclosure, a method of manufacturing a display window includes preparing a mother substrate, performing a salt treatment on the mother substrate to form a silicon-rich layer in a surface of the mother substrate to a first depth from the surface of the mother substrate, and removing the silicon-rich layer, wherein the first depth is greater than a depth of any cracks in the surface of the mother substrate, and a ratio of silicon content in the silicon-rich layer to a silicon content in the mother substrate is 1.2 to 1.4.