Hydrogen Release Layer Laser Separation for Display Substrate

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Solution Overview

Problem

Current methods for manufacturing display devices face challenges in improving display quality and production yield, particularly in separating display elements from supporting substrates without deformation or damage, leading to residual ashes and surface roughness issues.

Innovation Solution

A method involving a temporary substrate with a hydrogen-containing structure and a polymer film, where a laser beam is focused on the hydrogen structure to separate the temporary substrate from the polymer film, reducing residual ashes and surface roughness by generating internal pressure and controlled hydrogen release.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional methods are used to separate display elements from supporting substrates, then the separation process is simple, but the display device surface becomes rough and contains residual ashes

Engineering Contradiction:

Improvesurface qualityVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

A hydrogen-containing release layer is formed on the supporting substrate before forming the display device. This preliminary action enables selective removal of the release layer through laser irradiation, allowing clean separation of the display device from the supporting substrate without leaving residual ashes or causing surface roughness.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The hydrogen-containing release layer acts as an intermediary between the supporting substrate and the display device. It facilitates controlled separation by absorbing laser energy and generating internal pressure that selectively removes the release layer, leaving the display device surface clean and intact.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If laser beam is focused on the polymer film directly, then the temporary substrate can be removed, but the polymer film surface becomes damaged with residual ashes

Engineering Contradiction:

Improvesurface integrityVSAvoidsurface damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The hydrogen-containing release layer serves as an intermediary that absorbs the laser beam energy. When the laser beam irradiates the release layer, it generates internal pressure that removes the temporary substrate without directly heating or damaging the polymer film surface, thus preventing residual ashes and surface damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The conventional mechanical or thermal separation methods that directly contact the polymer film are replaced by a laser-based process that acts on the hydrogen-containing release layer. The laser energy is converted to internal pressure within the release layer, which mechanically separates the temporary substrate without direct contact with the polymer film.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If the display device is debonded from the supporting substrate without a release layer, then the process is straightforward, but deformation and damage occur

Engineering Contradiction:

Improveproduction yieldVSAvoiddevice quality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A hydrogen-containing release layer is preliminarily formed on the supporting substrate before the display device is fully assembled. This allows for controlled debonding later in the process without deforming or damaging the display device, thereby maintaining both high production yield and device quality.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The physical and chemical parameters of the release layer are specifically designed to enable selective removal. The hydrogen-containing release layer has specific absorption characteristics for laser wavelengths that allow it to be removed under laser irradiation without affecting the display device, enabling high-yield production with maintained device integrity.

Inventive Principle:

Principle #35Parameter changes

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 enhances the quality and production yield of display devices by minimizing surface defects and ensuring a smooth surface for subsequent components, improving the structural integrity and accuracy of the manufacturing process.

Implementation Method 1

a laser beam process is performed, to focus a laser beam on the hydrogen containing structure

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

focus a laser beam on the hydrogen containing structure

Methodology Applied

Scientific EffectThermal heating: Heating

Implementation Method 3

the hydrogen containing structure is formed on the temporary substrate... focus a laser beam on the hydrogen containing structure

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Data Source

PatentUS10906288B2Method for manufacturing display device

Publication Date: 2021.02.02 INNOLUX CORP

AI summary

A method for manufacturing a display device is disclosed, the method at least includes the following step: Firstly, a temporary substrate is provided, a hydrogen containing structure is formed on the temporary substrate, a polymer film is formed on the hydrogen containing structure, and a display element is formed on the polymer film. Afterwards, a laser beam process is performed, to focus a laser beam on the hydrogen containing structure, and the temporary substrate is then removed.