Flexible Substrate Separation Using a Slit-Forming Carrier Lift
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Solution Overview
Problem
The separation process of flexible substrates from rigid carrier substrates in flexible display device production often results in damage due to direct mechanical suction, leading to a low yield rate of intact flexible substrates.
Innovation Solution
A separating device and method that utilize a movable platen to form a slit between the carrier substrate and the flexible substrate, a separating sheet to separate the flexible substrate along the slit, and a suction head to remove the separated substrate, thereby avoiding direct pulling and enhancing yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical equipment directly suctions the flexible substrate to remove the carrier substrate, then the separation process is simple and fast, but the flexible substrate suffers pulling damage and yield rate decreases
Solution Approach 1:
The patent introduces a separating sheet as an intermediary between the flexible substrate and the suction head. The separating sheet is first inserted into the separation gap, then the suction head suctions the separating sheet rather than directly suctioning the flexible substrate. This intermediary approach allows the flexible substrate to be pulled out gently without direct mechanical stress, preventing pulling damage while maintaining separation efficiency
Solution Approach 2:
The patent segments the separation process into distinct stages: first inserting the separating sheet into the gap, then suctioning the separating sheet, and finally pulling out the flexible substrate. This segmentation allows each step to be optimized independently, ensuring both efficiency and substrate integrity
2Reliability
If a separating sheet is introduced to prevent pulling damage, then flexible substrate integrity is improved, but the separation process complexity increases
Solution Approach 1:
The separating sheet is designed to be self-inserting into the separation gap through simple mechanical motion. The sheet automatically positions itself between the flexible substrate and carrier substrate during the separation process, eliminating the need for complex positioning mechanisms or additional operational steps
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 described solution effectively prevents pulling damage during the separation process, thereby increasing the yield rate of flexible substrates and ensuring their integrity for further use in display devices.
Implementation Method 1
a movable platen, for raising the second divided area, thereby partially separating the carrier substrate from the flexible substrate, and thereby forming a slit
Implementation Method 2
a sensor disposed on a separating sheet, for detecting changes of light at the slit, thereby generating control signals
Implementation Method 3
a suction head, for removing the separated flexible substrate from the carrier substrate
Data Source
AI summary
A separating device and a method of separation are disclosed. The separating device and the method of separation are for separating a flexible substrate fixed on a carrier substrate having a first divided area and a second divided area, the flexible substrate includes an effective area defined corresponding to the first divided area and an ineffective area defined corresponding to the second divided area. The separating device comprises: a movable platen, for raising the second divided area, thereby partially separating the carrier substrate from the flexible substrate, and thereby forming a slit; a separating sheet, for separating the flexible substrate along the slit, thereby separating the effective area of the flexible substrate from the first divided area of the carrier substrate; and a suction head, for removing the separated flexible substrate from the carrier substrate.