Flexible Display Substrate Process Film for Batch Manufacturing
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Solution Overview
Problem
Conventional methods of manufacturing flexible display substrates are costly, prone to scratching and contamination, and suffer from static electricity issues, leading to reduced process efficiency and substrate reliability.
Innovation Solution
A method using a process film with specific layers (first and second base films, adhesion layers, and anti-static coatings) to laminate and cut a base layer into multiple substrates, ensuring protection and ease of handling, and a back film for rear surface protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to manufacture flexible display substrates one by one, then each substrate can be carefully processed, but the unit cost of production becomes expensive and productivity is low
Solution Approach 1:
The patent divides the manufacturing process into two stages: first, multiple substrates are processed simultaneously on a single large base layer (mass processing); second, the base layer is cut into individual substrates (segmentation). This allows high productivity during processing while maintaining quality control through the protective film system.
Solution Approach 2:
Multiple flexible display substrates are merged onto a single base layer for simultaneous processing. The base layer acts as a common support structure that enables batch processing of multiple substrates, significantly improving productivity while maintaining consistent quality across all substrates through the unified protective film system.
2Productivity
If the base layer is cut to complete individual substrates, then production is finalized, but the display portion and terminal portion may be scratched and static electricity or fine dust may become a problem
Solution Approach 1:
The protective film is applied to the base layer before any cutting or processing operations. This preliminary protection prevents scratches and contamination from occurring during subsequent manufacturing steps, including the cutting process that separates individual substrates.
Solution Approach 2:
The protective film acts as an intermediary layer between the base layer and external contaminants or mechanical elements during cutting. This intermediate layer absorbs the harmful effects of scratches and dust, protecting the underlying display structures while allowing the cutting process to proceed.
3Temperature
If glass substrate is used for FPD device manufacturing, then high thermal resistance and high transmittance are achieved, but impact resistance is poor and weight is relatively large
Solution Approach 1:
The patent changes the material parameter from glass to flexible resin materials (such as polyimide, polycarbonate, or polyester). This material substitution maintains adequate thermal resistance for display manufacturing while dramatically reducing substrate weight and improving flexibility and impact resistance.
Solution Approach 2:
The patent uses composite structures combining flexible resin base layers with protective films. This composite material approach achieves the desired balance between thermal resistance (for processing), weight reduction (for portability), and impact resistance (for durability) that single-material glass cannot provide.
4Stability of the object's composition
If adhesive is used to bond the base layer on glass substrate, then the base layer is fixed, but the manufacturing process becomes complex and requires additional bonding steps
Solution Approach 1:
The patent extracts and removes the adhesive layer from the manufacturing process. Instead of using adhesive to bond the base layer to the glass substrate, the base layer is directly formed on the glass substrate through deposition or lamination processes, simplifying the manufacturing process while maintaining stable fixation.
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
Improves manufacturing convenience and reliability by enabling simultaneous production of multiple substrates with reduced damage and static interference, enhancing process efficiency and substrate quality.
Implementation Method 1
a first anti-static coating layer (173) on the first base film (171) for preventing or reducing static electricity
Implementation Method 2
a first adhesion layer (172) under the first base film (171), such that the first base film is laminated on a base layer (130)
Data Source
AI summary
A method of manufacturing a flexible display substrate using a process film and a process film for manufacturing a flexible display substrate are provided. The method of manufacturing the flexible display substrate using the process film is as follows. A base layer for the flexible display substrate is prepared on a glass substrate. A packaging process is performed on the base layer to form a plurality of cells which are spaced apart from one another at a predetermined distance. The base layer is covered with the process film, after forming the plurality of cells. The base layer is separated from the glass substrate, while the base layer is laminated to the process film. The base layer is cut along each cell to form a plurality of flexible display substrates. Accordingly, the method of manufacturing the flexible display substrate using the process film is provided to improve the convenience of a manufacturing process and the reliability of the manufactured flexible display substrate by manufacturing the plurality of display substrates using the process film.