Glass Package Edge Coating to Fill Cutting Cracks
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Solution Overview
Problem
Glass substrates used in mini LED and micro-LED displays are prone to cracking during cutting due to cutting parameters or glass stress, leading to reduced structural stability and increased manufacturing costs.
Innovation Solution
A protective layer made of organic polymer is applied on the glass substrate to cover the cutting edge and fill cracks, preventing crack expansion and enhancing structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glass substrate is cut without protective mechanism, then cutting process is simple, but crack is formed in cutting edge reducing structural stability
Solution Approach 1:
A protective layer is formed on the glass substrate before the cutting process. This preliminary protective measure prevents cracks from forming at the cutting edge during the cutting process, thereby maintaining structural stability while keeping the manufacturing process relatively simple.
Solution Approach 2:
The protective layer acts as an intermediary between the cutting tool and the glass substrate. It absorbs the mechanical stress and impact during cutting, preventing direct transmission of force to the glass substrate that would cause cracking, thus preserving structural integrity.
2Stability of the object's composition
If protective layer is applied to cover cutting edge, then crack expansion is prevented improving structural stability, but manufacturing process complexity increases
Solution Approach 1:
A thin protective layer (film) is applied to the glass substrate surface. This thin film structure provides crack prevention functionality while adding minimal complexity to the manufacturing process. The thin film nature allows for simple application methods and does not significantly alter the overall device structure.
Solution Approach 2:
The protective layer undergoes a parameter change through heating that causes it to flow and fill existing cracks. This phase change or viscosity change allows the protective layer to actively repair defects rather than just prevent them, enhancing structural stability without requiring complex additional manufacturing steps.
3Productivity
If protective layer flows to fill crack, then yield is improved by preventing crack expansion, but additional heating step increases manufacturing time
Solution Approach 1:
The heating step that causes the protective layer to flow and fill cracks is combined with or integrated into the existing manufacturing process flow. By merging this functional heating step with other necessary heating or processing steps, the additional time required is minimized while still achieving the crack-filling function that improves yield.
Solution Approach 2:
The protective layer utilizes a phase transition or viscosity change upon heating to flow into and fill cracks. This self-healing mechanism occurs automatically during the heating process without requiring additional manual intervention or complex equipment, thereby improving yield with minimal time penalty.
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 protective layer reduces the chances of cracking and improves yield and manufacturing efficiency by stabilizing the glass substrate.
Implementation Method 1
heating the protective layer such that a portion of the protective layer flows toward a bottom surface of the glass substrate
Implementation Method 2
heating the protective layer such that a portion of the protective layer flows
Data Source
AI summary
A manufacturing method of a package structure includes: forming a redistribution layer on a top surface of a glass substrate; forming a protective layer on the top surface of the glass substrate; cutting the glass substrate and the protective layer such that the glass substrate has a cutting edge, in which a crack is formed in the cutting edge of the glass substrate; and heating the protective layer such that a portion of the protective layer flows towards a bottom surface of the glass substrate to cover the cutting edge of the glass substrate and fill the crack in the cutting edge of the glass substrate.