Hybrid Glass Panel Lamination for Breakage-Resistant Processing
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Solution Overview
Problem
Glass panels and substrates are fragile and prone to breakage in traditional semiconductor manufacturing equipment, leading to operational issues, material loss, and safety hazards, and require significant modifications to existing production lines.
Innovation Solution
A hybrid glass substrate with a glass core embedded in an organic frame, processed using an automated lamination system that includes an alignment and lamination module, allowing for integration into traditional machinery without fragility limitations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glass core panels are processed through traditional semiconductor manufacturing equipment, then production can continue using existing infrastructure, but the glass panels are highly susceptible to breakage due to their fragility and rigidity
Solution Approach 1:
The patent applies composite materials by combining glass core panels with protective framing structures and cushioning materials. The glass panel is integrated into a composite assembly that includes flexible framing elements and shock-absorbing components, allowing the fragile glass to withstand the mechanical stresses of traditional semiconductor manufacturing equipment while maintaining its functional properties.
Solution Approach 2:
The patent implements beforehand cushioning by incorporating protective framing and cushioning materials around the glass core panel before processing. These protective structures are pre-installed to absorb mechanical shocks and prevent breakage during handling and processing through traditional equipment, thereby maintaining reliability without requiring modifications to the manufacturing infrastructure.
2Device complexity
If traditional machinery is used without modifications, then equipment complexity remains low, but operational issues such as jamming or misalignment occur due to dimensional variations in glass core panels
Solution Approach 1:
The patent applies dynamics by incorporating flexible framing structures and adjustable positioning mechanisms that can adapt to dimensional variations in glass core panels. These dynamic elements allow the protective assembly to accommodate slight variations in panel dimensions without causing misalignment or jamming, ensuring smooth operation through traditional equipment without requiring complex modifications to the machinery.
3Productivity
If glass core panels are integrated into existing production lines, then production yield may be maintained, but material loss occurs due to breakage translating to wasted raw materials
Solution Approach 1:
The patent implements beforehand cushioning with protective framing and shock-absorbing materials that prevent breakage during processing. This protective architecture ensures that glass core panels survive the manufacturing process intact, eliminating material loss and maintaining high production yield without requiring changes to the existing production line infrastructure.
4Productivity
If glass core panels are processed in traditional equipment, then production efficiency is maintained, but safety hazards arise from shattered glass posing risks to personnel
Solution Approach 1:
The patent applies the intermediary principle by introducing protective framing structures and containment mechanisms between the glass core panel and the processing environment. These intermediary protective elements prevent glass breakage and contain any potential shards, eliminating safety hazards to personnel while allowing continuous efficient processing through traditional equipment without requiring production slowdowns or additional safety infrastructure.
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 hybrid glass substrate can withstand aggressive processing in traditional equipment, reducing breakage and enabling safe, efficient production with minimal modifications.
Implementation Method 1
an alignment module integrated to the lamination module
Implementation Method 2
a lamination module configured downstream of the alignment module operable to form a hybrid panel from the glass core
Implementation Method 3
form a hybrid panel from the glass core
Implementation Method 4
form a hybrid panel from the glass core
Data Source
AI summary
The present disclosure generally relates to a glass substrate comprising a glass core, a first buffer layer in contact with the glass core, a composite build-up layer incorporated in the first buffer layer, and an electrically conductive frame, wherein the first buffer layer, the composite build-up layer, and the electrically conductive frame, are peripherally disposed around the glass core. A method and a system are also disclosed.