Lamination Substrate Removal via Laser Heating and Segmented Protection
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Solution Overview
Problem
The existing manufacturing process for display devices faces challenges in preventing damage to the sheet substrate and the accumulation of foreign substances during the separation of substrates, which complicates the formation of accurate divider lines and increases manufacturing complexity.
Innovation Solution
A method involving the preparation of a lamination with a sheet substrate and a display element layer, followed by adhering a protective film to cover the display areas, forming divider lines by removing a portion of the blank region, and irradiating the sheet substrate with laser beams from a non-contact side to reduce adhesion and facilitate safe removal of the substrate, thereby preventing damage and foreign substance accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the substrate is removed from the sheet substrate by irradiating with laser beams to alter the surface by heat, then the adhesion between substrate and sheet substrate is maintained in the edges, but this causes damage to the sheet substrate when the substrate is removed
Solution Approach 1:
The invention divides the sheet substrate into different regions: a first region (display area) where the substrate is removed, and a second region (edge area) where the substrate remains adhered. This segmentation allows selective removal of the substrate from the display area while maintaining adhesion in the edge area, preventing sheet substrate damage.
Solution Approach 2:
The invention applies different treatments to different regions of the sheet substrate. The first region receives laser irradiation to remove the substrate, while the second region maintains its adhesive properties. This local differentiation enables precise control over where substrate removal occurs, solving the contradiction between maintaining adhesion and preventing damage.
2Strength
If a protective film is adhered to the sheet substrate to cover the entire sheet substrate before forming divider lines, then the sheet substrate is protected, but the laser beams are not directly irradiated to the sheet substrate making it difficult to form divider lines at the estimated depth
Solution Approach 1:
The protective film is segmented into different coverage areas: it covers the first region (display area) where substrate removal is needed, but does not cover the second region (edge area) where divider lines are formed. This selective coverage allows laser beams to directly irradiate the sheet substrate in the second region for precise divider line formation while still protecting the first region.
Solution Approach 2:
Instead of covering the entire sheet substrate with the protective film, the invention applies the protective film only to the necessary display area. This partial coverage is sufficient to protect the critical display region while allowing direct laser access to the edge area for divider line formation, achieving both protection and precision.
3Reliability
If protective films are adhered to respective display devices, then each display device is protected, but the number of protective films needed to be adhered is increased
Solution Approach 1:
The invention merges the protective function into a single unified protective film that covers multiple display devices simultaneously. Instead of adhering separate protective films to each individual display device, one protective film is adhered to the sheet substrate covering the first region, providing protection for all display devices in that region. This reduces the number of protective films from multiple individual films to a single collective film.
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 approach effectively prevents damage to the sheet substrate and foreign substance remnants, simplifying the manufacturing process by allowing precise formation of divider lines and easy removal of substrates, enhancing the convenience and efficiency of display device production.
Implementation Method 1
irradiating the sheet substrate with a laser beam from a side of the substrate that is not in contact with the sheet substrate
Implementation Method 2
irradiating the sheet substrate with laser beams and removing the sheet substrate altered by heat of the laser beams
Implementation Method 3
forming a divider line by removing a portion of the blank region of the lamination after adhering the protective film
Data Source
AI summary
A lamination includes a sheet substrate and a display element layer. The sheet substrate includes a plurality of product regions cut out into a plurality of products and a blank region surrounding the product regions. The display element layer is formed on each of a plurality of display areas placed on each of the plurality of product regions for displaying an image. The sheet substrate adheres to a top of a substrate. The substrate has light transmissivity. A protective film is adhered to the lamination so as to cover the display areas. A divider line is formed in a blank region that surrounds the product regions by removing a portion of the lamination. The substrate is removed from the sheet substrate by irradiating the sheet substrate with a laser beam.