Electrostatic Roll Transfer for Flexible Substrate Protection

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Solution Overview

Problem

Existing substrate transferring methods for flexible display panels often damage the processed surface during transfer, leading to reduced productivity, reliability, and display quality, and increased manufacturing costs due to direct contact and potential disconnection of signal wiring, as well as the need for additional protective measures like separate protecting sheets.

Innovation Solution

A substrate transferring unit using a combination of first and second transferring rolls with electrostatically charged central and outer portions, which alternately contact the substrate's surface without direct contact to the processed surface, utilizing electrostatic induction for frictional force to transfer the substrate, thereby protecting the processed surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If transferring rolls make direct contact with the processed surface of the substrate, then the transferring force is sufficient, but the processed surface may be damaged (scratched, wired disconnected, stained)

Engineering Contradiction:

Improvetransferring forceVSAvoidsurface damage

Core Design Contradiction:

ForceVSObject-affected harmful factors

Solution Approach 1:

A protecting sheet is introduced as an intermediary layer between the transferring rolls and the processed surface of the substrate. The protecting sheet has a first surface that contacts the processed surface and a second surface that contacts the transferring rolls, thereby preventing direct contact and potential damage while still enabling force transmission for substrate transfer.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The protecting sheet is implemented as a thin, flexible film that can conform to the processed surface of the substrate while being sufficiently robust to resist scratching and damage from the transferring rolls. This thin film structure provides protection without significantly increasing the overall thickness or rigidity of the substrate assembly.

Inventive Principle:

Principle #30Flexible shells and thin films

2Object-affected harmful factors

If a separate protecting sheet is attached to protect the processed surface, then the processed surface is protected, but the manufacturing cost increases and the processed surface may be stained during attachment/detachment

Engineering Contradiction:

Improvesurface protectionVSAvoidmanufacturing process complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The protecting sheet is merged with the substrate to form an integrated assembly where the protecting sheet and substrate are attached in a first region and separated in a second region. This integration allows the protecting sheet to be applied once and remain attached throughout the manufacturing process, eliminating the need for repeated attachment and detachment operations that increase complexity and risk of contamination.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The protecting sheet is attached to the processed surface before the substrate undergoes subsequent manufacturing processes. This preliminary protection is maintained throughout the manufacturing sequence, preventing the need for re-protection later and avoiding the complications of multiple attachment/detachment cycles.

Inventive Principle:

Principle #10Preliminary action

3Object-affected harmful factors

If an air levitation transferring roll is used to transfer the substrate, then the processed surface is protected, but noise is generated and manufacturing cost increases

Engineering Contradiction:

Improvesurface protectionVSAvoidnoise

Core Design Contradiction:

Object-affected harmful factorsVSObject-generated harmful factors

Solution Approach 1:

Instead of using air levitation to prevent contact, a protecting sheet serves as the intermediary that allows controlled mechanical contact through the sheet while protecting the processed surface. This approach avoids the noise generation associated with air levitation systems while still achieving surface protection.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 protects the processed surface of substrates during transfer, improving productivity, reliability, and display quality while reducing manufacturing costs by avoiding direct contact and allowing for vacuum processing without noise generation.

Implementation Method 1

utilizing electrostatic induction for frictional force to transfer the substrate

Methodology Applied

Scientific EffectElectrostatic induction: Electrostatic Induction

Data Source

PatentUS9663314B2Roll-to-roll substrates transferring unit and method of processing substrates using the substrates transferring unit

Publication Date: 2017.05.30 SAMSUNG DISPLAY CO LTD

AI summary

A flexible and continuous substrates-conveying sheet has a plurality of to be processed substrates disposed on or in it. A nondestructive transferring unit includes a plurality of first transferring rolls and a plurality of second transferring rolls. The first transferring rolls make contact with a first surface of the substrates-conveying sheet where that surface can have electrostatically-induced charge formed thereon. Each of the first transferring rolls includes a first central portion charged with a positive electric charge and a first outer portion surrounding the first central portion. The second transferring rolls make contact with the first surface of the substrates-conveying sheet. The second transferring rolls are disposed alternately with the first transferring rolls. Each of the second transferring rolls includes a second central portion charged with a negative electric charge and a second outer portion surrounding the second central portion.