Glass Substrate Electronic Device Manufacturing via Segmented Tempering
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Solution Overview
Problem
The existing methods for manufacturing electronic devices using glass substrates face challenges in productivity and durability, particularly in the sheet and cell methods, where the side surfaces of the substrates are weakened, and patterning defects can occur due to machining tolerances in the cell method.
Innovation Solution
A method involving the preparation of first and second mother glass substrates, where device cells and cover cells are formed with partial connections through separating portions, aligned and laminated to form electronic devices, and then separated, with alignment keys used for precise alignment and tempering to enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the sheet method is used where mother glass is entirely tempered and then cut, then the tempering process is simple, but the side surfaces (cut surfaces) are not tempered and strength is weakened
Solution Approach 1:
The mother glass is divided into multiple device cells before the cutting step, with each cell remaining partially connected to the mother glass through separating portions. This segmentation allows selective tempering of specific regions while maintaining structural integrity during processing.
Solution Approach 2:
The device cells are formed and patterned on the mother glass before the final cutting and separation. This preliminary formation of cells with separating portions allows the tempering process to be applied to the entire mother glass including the side surfaces, while the separating portions remain untempered for subsequent separation.
2Strength
If the cell method is used where mother glass is cut into cells before patterning, then all surfaces can be tempered, but productivity is reduced due to sequential processing
Solution Approach 1:
Multiple device cells are formed and patterned simultaneously on a single mother glass substrate. The separating portions connect multiple cells to the mother glass, allowing batch processing of multiple devices in parallel, thereby significantly improving productivity compared to sequential cell-by-cell processing.
Solution Approach 2:
The mother glass serves multiple functions: it provides structural support during processing, enables simultaneous patterning of multiple cells, and allows batch tempering of all surfaces. The separating portions serve dual purposes of maintaining connection during processing and enabling final separation.
3Productivity
If the cell method is used with jig support for tempering and patterning, then individual cells can be processed, but patterning defects occur due to machining tolerance
Solution Approach 1:
The device cells are extracted from the mother glass through the separating portions after batch patterning. This eliminates the need for jig support during patterning, removing the source of machining tolerance errors while maintaining the ability to process individual cells.
Solution Approach 2:
Multiple device cells are created as copies on the same mother glass substrate through simultaneous patterning. This batch copying process eliminates the need for repeated jig positioning and machining, thereby eliminating patterning defects caused by machining tolerance accumulation.
Data Source
AI summary
Provided is a method of manufacturing an electronic device, the method including: preparing first mother glass and second mother glass; forming, on the first mother glass, a plurality of device cells partially connected to the first mother glass through a plurality of first separating portions; patterning a device circuit on each of the plurality of device cells; forming, on the second mother glass, a plurality of cover cells partially connected to the second mother glass through a plurality of second separating portions; forming a plurality of electronic devices by laminating the first mother glass and the second mother glass together such that the plurality of device cells are respectively aligned to the plurality of cover cells; and separating the plurality of electronic devices from the first mother glass and the second mother glass by cutting the plurality of first separating portions and the plurality of second separating portions.