Electronic Structure Support Layout to Prevent Film Drooping
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Solution Overview
Problem
Existing methods for manufacturing electronic structures with composite films face challenges in achieving good separation from substrates, as the area of the anchor is smaller than the electronic structure, leading to potential drooping and adhesion issues.
Innovation Solution
The electronic structure includes a substrate with a support layer and micro-spacers, where the support layer has a smaller area than the composite film, and the micro-spacers are formed by a different material, allowing for controlled adhesion and easy separation by adjusting the adhesion force between the composite film and the support layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the anchor area is made smaller than the electronic structure area, then the separation between composite film and substrate is improved, but the electronic structure may droop and adhere strongly to the substrate
Solution Approach 1:
The support structure is divided into multiple discrete supports (first support and second support) positioned at different locations beneath the electronic structure. This segmentation allows the composite film to be supported at multiple points, preventing drooping while maintaining controlled separation from the substrate. The first support is positioned closer to the center and the second support is positioned away from the center, creating a distributed support system that addresses both separation and stability requirements.
2Stability of the object's composition
If the anchor area is made larger than the electronic structure area, then the structural stability is improved, but the separation between composite film and substrate deteriorates
Solution Approach 1:
Different regions of the support structure have different characteristics. The first support has a first contact area with the composite film and the second support has a second contact area. By making the contact areas different (with the second contact area being smaller than the first), the patent creates local variations in adhesion strength. This allows stronger adhesion under the center (first support) for stability and weaker adhesion at the periphery (second support) for easier separation, resolving the contradiction between stability and separation quality.
3Reliability
If the contact area between support and composite film is made smaller, then the separation is improved, but the structural support is reduced
Solution Approach 1:
The patent introduces a vertical dimension by positioning supports at different heights relative to the composite film. The first support extends higher (first extension height) than the second support (second extension height). This dimensional variation allows the first support to provide stronger structural support and adhesion when needed, while the second support provides weaker support for controlled separation. The different extension heights create a three-dimensional support configuration that simultaneously achieves both strong support and easy separation.
Data Source
AI summary
An electronic structure includes: a substrate having a first surface; a functional element unit including a functional element having an electronic function, and a protector covering the functional element, the functional element unit having a second surface facing the first surface; a support disposed between the first surface and the second surface, the support supporting the second surface; and a projection disposed on a first surface side of the substrate, the projection projecting toward the functional element unit. The support has a third surface in contact with the second surface of the functional element unit, the third surface having an area smaller than an area of the second surface. The projection has a fourth surface in contact with or close to the functional element unit, the fourth surface having an area smaller than the area of the second surface, the projection being formed by a different material from the support.