Flexible Display Substrate Laser Separation via Blocking Film
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Solution Overview
Problem
Conventional methods for manufacturing display device substrates are limited in producing various shapes beyond rectangular forms, requiring additional complex processes and struggling with the handling of flexible substrates due to their flexible characteristics.
Innovation Solution
A method involving a supporting substrate with a blocking film and a substrate layer, where the blocking film is patterned and the substrate layer is formed to cover it, with portions removed to space the films apart, allowing for easy separation of the substrate layer from the supporting substrate using a laser beam, enabling flexible and varied substrate shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible substrate is used to enable various substrate shapes, then adaptability is improved, but ease of operation deteriorates due to handling difficulties
Solution Approach 1:
A blocking film is introduced as an intermediary layer between the flexible substrate layer and the supporting substrate. This blocking film enables selective separation of the substrate layer from the supporting substrate while maintaining the flexible substrate's shape versatility. The blocking film acts as a mediator that facilitates easy handling during manufacturing while preserving the final flexible product's adaptability to various shapes.
2Manufacturing precision
If additional processes are added to manufacture non-rectangular substrates, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The blocking film is formed in advance on the supporting substrate before the flexible substrate layer is deposited. This preliminary formation of the blocking film with the desired pattern allows the substrate layer to be separated in various shapes without requiring additional complex processing steps later. The shape definition is performed upfront, simplifying the overall manufacturing process while maintaining precision.
3Ease of operation
If the substrate layer is separated from the supporting substrate, then ease of operation is improved, but the substrate layer edges may be damaged
Solution Approach 1:
The blocking film serves as a protective intermediary that prevents direct contact and potential damage between the substrate layer edges and the supporting substrate during separation. By introducing this intermediate layer, the substrate layer can be easily separated in various shapes while the blocking film protects the edges from mechanical damage, maintaining both ease of operation and edge integrity.
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 simplifies the manufacturing process by allowing for the creation of flexible substrates in various shapes without damaging the edges, reducing the complexity of producing non-rectangular display devices and enhancing the flexibility of display device designs.
Implementation Method 1
separating the substrate layer from the supporting substrate by irradiating the second surface of the supporting substrate with a laser beam
Implementation Method 2
The blocking film may include a material which absorbs about 90% or more laser beam having a wavelength of about 300 nm
Data Source
AI summary
Provided herein is a method of manufacturing a substrate for a display device, the method including: preparing a supporting substrate having a first surface and a second surface opposite to the first surface; patterning a blocking film on the first surface of the supporting substrate; forming a substrate layer on the supporting substrate to cover the blocking film; removing at least a portion of the substrate layer to space the blocking film apart from the substrate layer by a predetermined distance; and separating the substrate layer from the supporting substrate.