Display Device Protective Film Separation Apparatus
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Solution Overview
Problem
The manufacturing process of display devices faces high defect rates due to challenges in accurately removing protective films without applying excessive pressure, which can damage the substrates and result in incomplete separation.
Innovation Solution
A manufacturing apparatus and method that utilize a separation module with a pressure sensor and driver controlled by a controller to precisely apply and monitor pressure, ensuring the protective film is separated without overpressing the substrate, even on uneven stages, by defining cutting lines and using a temporary adhesive layer for easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressure is applied to separate the protective film from the substrate, then separation is achieved, but excessive pressure damages the substrate
Solution Approach 1:
The patent employs a pressure sensor to detect the pressure applied during protective film separation and feeds this information back to a controller. The controller adjusts the driving motor based on the pressure feedback to maintain pressure within a safe range, preventing substrate damage while ensuring complete separation. This closed-loop control system resolves the contradiction by dynamically balancing separation effectiveness with substrate protection.
Solution Approach 2:
The system dynamically changes the pressure parameter during the separation process based on real-time sensor feedback. By adjusting pressure levels according to the actual separation progress and substrate conditions, the system achieves effective separation without applying excessive pressure that could damage the substrate.
2Manufacturing precision
If pressure sensor and control system are added, then separation control precision is improved, but device complexity increases
Solution Approach 1:
The system uses an adhesive layer between the protective film and substrate that naturally facilitates separation when appropriate pressure is applied. The adhesive's properties enable the separation process to proceed with minimal external intervention, reducing the need for complex control mechanisms while maintaining separation effectiveness.
3Ease of operation
If uniform pressure is applied across the substrate, then separation is simplified, but height variations cause incomplete separation
Solution Approach 1:
The pressure sensor detects pressure variations caused by substrate height differences and feeds this information back to the controller. The controller adjusts the pressure application in real-time to compensate for height variations, ensuring complete separation across the entire substrate surface while maintaining operational simplicity.
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 solution effectively reduces defect rates by ensuring accurate and controlled separation of protective films, preventing substrate damage and ensuring complete removal, even on substrates with height variations, thereby improving the manufacturing efficiency and quality of display devices.
Implementation Method 1
a pressure sensor to measure an intensity of a pressure applied to the separation structure
Implementation Method 2
the pressure sensor may include a piezoelectric element
Data Source
AI summary
A manufacturing apparatus of a display device includes: a stage to support a work substrate covered by a work protective film; a separation module including a separation structure, and a pressure sensor to measure an intensity of a pressure applied to the separation structure; a driver to control a position of the separation module; and a controller to control the separation module and the driver.