Flexible Display Substrate Separation via Edge Sealant and Vacuum Bonding
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Solution Overview
Problem
The manufacturing of flexible display devices faces challenges due to the pliability of substrates, which makes it difficult to accurately perform the manufacturing process, leading to issues with peeling off the flexible substrate from the support substrate, residual adhesive, and potential damage to thin film patterns.
Innovation Solution
A method involving a support substrate with a sealant coated on its edges, combining the flexible substrate in a vacuum state, hardening the sealant, forming display components, and cutting along a defined line to separate the flexible substrate from the support substrate, eliminating the need for adhesive removal and reducing the risk of pattern damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If adhesive material is used to fasten flexible substrate to support substrate, then the flexible substrate can be stably supported and easily handled, but it becomes difficult to peel off the flexible substrate from the support substrate and adhesive residues remain on the flexible substrate
Solution Approach 1:
A release film is introduced as an intermediary layer between the adhesive material and the flexible substrate. This release film allows the adhesive to bond strongly to the support substrate while providing a non-stick surface that enables easy peeling of the flexible substrate assembly from the support substrate without leaving adhesive residues on the flexible substrate.
Solution Approach 2:
The release film is applied selectively only in the regions where peeling is required, while adhesive material is applied in regions where bonding is needed. This localized application of different materials allows the flexible substrate to be stably supported during manufacturing while enabling clean separation afterward.
2Stability of the object's composition
If the flexible substrate is entirely adhered to the support substrate, then stable support is achieved, but peeling off becomes difficult and requires additional cleaning processes
Solution Approach 1:
The release film serves as a mediator that prevents adhesive contamination of the flexible substrate while maintaining stable support during the manufacturing process. This eliminates the need for additional cleaning processes after peeling, saving time and simplifying the manufacturing workflow.
3Ease of manufacture
If the flexible substrate is bent during peeling process, then separation from support substrate is achieved, but thin film patterns can be damaged
Solution Approach 1:
The release film provides a non-stick interface that allows the flexible substrate to be peeled off flat without requiring bending or forcing. This maintains the integrity of thin film patterns while achieving complete separation from the support substrate.
Solution Approach 2:
Instead of bending the flexible substrate to achieve separation, the invention inverts the approach by using a release film that enables flat peeling. The separation is achieved through the release film's non-stick properties rather than mechanical deformation of the flexible substrate.
4Volume of moving object
If plastic or metal foil substrate is used instead of glass substrate, then the display device becomes thinner and more flexible, but the substrate is more difficult to handle during manufacturing
Solution Approach 1:
The flexible substrate is combined with the support substrate through adhesive bonding (with release film intervention) to create a composite structure. This merged structure provides the handling stability of glass while maintaining the thin and flexible characteristics of plastic or metal foil substrates during manufacturing operations.
Solution Approach 2:
The release film acts as a temporary intermediary that enables easy handling of the thin flexible substrate during manufacturing by preventing adhesive contamination and facilitating clean separation afterward, making thin substrates as easy to handle as glass during the manufacturing process.
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 allows for precise separation of the flexible substrate without adhesive residue and minimizes damage to display components, enhancing the reliability and efficiency of the flexible display device manufacturing process.
Implementation Method 1
the sealant is hardened
Implementation Method 2
combining a flexible substrate and the support substrate coated with the sealant in a vacuum state
Data Source
AI summary
A method of manufacturing a flexible display device is disclosed. The flexible display device manufacturing method includes: preparing a support substrate; coating a sealant on edge areas of the support substrate; combining a flexible substrate and the support substrate coated with the sealant in a vacuum state; hardening the sealant between the support substrate and the flexible substrate; forming display components used in a configuration of the flexible display device on the flexible substrate; and cutting the flexible substrate along a cutting line on the flexible substrate to separate the flexible substrate from the support substrate.