Flexible Display Substrate Peeling via Separation Pattern Layer

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Solution Overview

Problem

The manufacturing of flexible display substrates is challenging due to the difficulty in accurately fixing and peeling the flexible substrate from a rigid support substrate without causing deformation or damage, leading to low yield and high costs.

Innovation Solution

A method involving a separation pattern layer with thermally deformable or gas/liquid-filled units on a support substrate, combined with an adhesion layer, allows for uniform gap generation between the flexible and support substrates during peeling, facilitating easy separation and reducing deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the flexible substrate is firmly combined with the support substrate, then the position and flatness are accurately fixed, but the peeling process causes deformation and displacement of electronic elements

Engineering Contradiction:

Improveposition and flatness accuracyVSAvoidpeeling quality

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The support substrate is divided into multiple separable sections or layers, allowing the flexible substrate to be peeled off in segments rather than as a whole, reducing deformation stress on electronic elements during separation

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An intermediary layer or release coating is introduced between the flexible substrate and support substrate, facilitating easy separation while maintaining firm bonding during the manufacturing process, thus enabling accurate positioning without peeling deformation

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If conventional peeling methods are used, then the flexible substrate can be separated from the support substrate, but excessively long time is consumed or the flexible display substrate is easily damaged

Engineering Contradiction:

Improvepeeling capabilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The mechanical peeling process is replaced with thermal or chemical methods. Heating the support substrate to a specific temperature or applying a chemical solution weakens the adhesion between substrates, enabling rapid and damage-free separation without excessive time consumption

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The adhesion parameters between substrates are dynamically changed during the process. Strong adhesion is maintained during manufacturing, then adhesion is reduced through temperature or chemical parameter changes to enable quick peeling, improving both ease of manufacture and productivity

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If a laser beam is used for peeling processing, then the peeling can be controlled, but the laser beam unavoidably damages the display elements due to their thin pattern layers

Engineering Contradiction:

Improvepeeling control precisionVSAvoidlaser damage to display elements

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

A laser-absorbing intermediary layer is placed between the laser beam and the thin pattern layers of display elements. This intermediary layer absorbs the laser energy and converts it to thermal energy for controlled peeling, protecting the display elements from direct laser damage while maintaining peeling precision

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The direct laser peeling method is replaced with indirect thermal processing. The laser heats an intermediary layer or the support substrate rather than directly irradiating the thin pattern layers, achieving controlled peeling without damaging the display elements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach enhances the yield and reduces manufacturing costs by ensuring smooth peeling of the flexible display substrate without deformation, improving the overall efficiency of the process.

Implementation Method 1

forming, on a support substrate, a separation pattern layer comprising a plurality of separation units arranged at intervals

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS10205095B2Mother substrate for flexible display substrate and method of manufacturing flexible display substrate

Publication Date: 2019.02.12 BOE TECHNOLOGY GROUP CO LTD

AI summary

Embodiments of the present invention disclose a method of manufacturing a flexible display substrate. The method includes steps of: forming, on a support substrate, a separation pattern layer comprising a plurality of separation units arranged at intervals; forming an adhesion layer on the support substrate formed with the separation pattern layer; forming a flexible base substrate on the adhesion layer and forming a display element on a side of the flexible base substrate opposite to the adhesion layer; performing a peeling preprocessing on the support substrate, and peeling the flexible base substrate from the support substrate to form the flexible display substrate.