Dummy Substrate Protrusions for Flexible Display Panel Separation
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Solution Overview
Problem
The challenge in manufacturing display panels is the difficulty in separating flexible substrates from support substrates without damaging the materials, leading to defects in the display panel quality, especially when forming display areas at corners where materials tend to be separated unintentionally.
Innovation Solution
A method involving a support substrate with distinct areas, where a blocking layer and substrate material layers are formed, and a dummy substrate with protrusions is created to prevent unwanted separation of materials during the separation process, using a laser to separate the substrate from the support substrate while keeping the blocking layer intact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a flexible substrate is used to enable display areas at corners, then the display area is extended, but materials are separated unintentionally during separation from support substrate
Solution Approach 1:
The substrate material layer is segmented into multiple layers (first substrate material layer and second substrate material layer) with different separation characteristics. The first layer is designed to separate from the support substrate while the second layer remains attached, preventing unwanted material separation and enabling corner display areas.
Solution Approach 2:
Different regions of the substrate structure are given different properties: the first substrate material layer has properties optimized for separation from the support substrate, while the second substrate material layer has properties that prevent separation. This local differentiation allows corner display areas to be formed without material separation defects.
2Ease of operation
If flexible substrate is easily bent for manufacturing, then handling is difficult, but separation process becomes problematic
Solution Approach 1:
The substrate structure is divided into multiple layers with distinct separation behaviors. The first substrate material layer is designed to separate cleanly from the support substrate, while the second layer remains attached, ensuring reliable separation process despite the flexibility of the overall substrate structure.
3Area of stationary object
If display area is extended to corners, then non-display area is reduced, but material separation errors occur
Solution Approach 1:
The substrate material layer is divided into first and second layers with different separation characteristics. This segmentation allows the display area to be extended to corners while preventing material separation errors through the differential separation behavior of the two layers.
Solution Approach 2:
The second substrate material layer is positioned to provide local quality control at critical regions, preventing separation errors while allowing the display area to extend to corners. This local reinforcement ensures manufacturing precision is maintained despite the extended display area.
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 improves the manufacturing quality of display panels by preventing material separation errors, allowing for the formation of display areas even at corners without damage, thus extending the display area and reducing non-display areas.
Implementation Method 1
separating the substrate from the support substrate, wherein the dummy substrate includes a plurality of protrusions protruding toward the substrate
Implementation Method 2
separating the substrate from the support substrate
Data Source
AI summary
A method of manufacturing a display panel includes: preparing a support substrate including a first area and a second area that are spaced apart from each other, and a third area between the first area and the second area; forming, on the support substrate, a blocking layer located in the first area; forming, on the support substrate, a substrate material layer located in the first through third areas; removing a portion of the substrate material layer corresponding to the third area, to form a dummy substrate in the first area and a substrate in the second area; and separating the substrate from the support substrate, wherein the dummy substrate includes a plurality of protrusions protruding toward the substrate, and the substrate defines a plurality of through-portions corresponding to the plurality of protrusions, wherein an edge of each of the plurality of protrusions includes an uneven portion.