Laser Peeling Defect Detection in Display Manufacturing
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Solution Overview
Problem
The existing manufacturing method for display devices is prone to flaws due to variations in laser intensity caused by foreign matter or damaged substrates, leading to tearing and peeling defects, which are not detectable until after completion.
Innovation Solution
A method and apparatus that irradiate the resin layer with laser light from the back of the substrate, acquire optical information of the peeled substrate, and detect defects before completing the display devices, allowing for identification and processing of flawed units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser irradiation is performed on the resin layer to peel the substrate, then the substrate can be separated from the layered body, but variations in laser intensity due to foreign matter or damaged substrate portions cause tearing and peeling defects in the display devices
Solution Approach 1:
The patent performs preliminary inspection of the substrate before laser peeling by acquiring optical information and detecting defects such as foreign matter or damaged portions. This preliminary detection allows the system to identify problematic areas and adjust laser irradiation parameters or skip irradiation in those regions, preventing tearing and peeling defects while maintaining effective substrate peeling in sound areas.
2Productivity
If electronic circuit boards are mounted on individual pieces before completion, then the display device can be assembled, but flaws detectable after completion cannot be identified beforehand
Solution Approach 1:
The patent performs preliminary inspection of the substrate before laser peeling by acquiring optical information and detecting defects such as foreign matter or damaged portions. This preliminary detection allows the system to identify problematic areas and adjust laser irradiation parameters or skip irradiation in those regions, preventing tearing and peeling defects while maintaining effective substrate peeling in sound areas.
Solution Approach 2:
The patent implements a feedback mechanism where optical information is acquired from the substrate, defect detection results are analyzed, and this information feeds back to control the laser peeling process. The system adjusts laser irradiation based on detected defect locations, ensuring that areas with foreign matter or damage are not subjected to laser treatment that would cause defects, thereby maintaining high reliability while enabling early flaw identification.
3Productivity
If laser intensity varies due to foreign matter or damaged portions in the substrate, then the laser peeling process can proceed, but tearing occurs in the resin layer and defects occur in the layered body
Solution Approach 1:
The patent implements a feedback mechanism where optical information is acquired from the substrate, defect detection results are analyzed, and this information feeds back to control the laser peeling process. The system adjusts laser irradiation based on detected defect locations, ensuring that areas with foreign matter or damage are not subjected to laser treatment that would cause defects, thereby maintaining high reliability while enabling early flaw identification.
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
Enables the identification and removal of flawed display devices before completion, reducing manufacturing defects and improving yield.
Implementation Method 1
the resin layer is irradiated with laser from a back face of the substrate and the substrate is peeled from the layered body using a laser peeling device
Implementation Method 2
the resin layer is irradiated with laser from a back face of the substrate and the substrate is peeled from the layered body
Data Source
AI summary
Provided is a manufacturing method of a display device in which, after a layered body including a resin layer, a TFT layer, and a light emitting element layer is formed on a substrate configured to form a plurality of display devices, the resin layer is irradiated with laser from a back face of the substrate and the substrate is peeled from the layered body using a laser peeling device. The manufacturing method of a display device includes acquiring optical information of the substrate that is peeled off, detecting each acquisition result of the plurality of display devices from each assigned position of the plurality of display devices relative to the substrate, and performing predetermined processing on the display device in a case that the acquisition result of the display device exceeds a threshold value.