Magnetic Layer on Dummy Region for Display Substrate Evaporation
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Solution Overview
Problem
Large-sized display substrates tend to droop during the evaporation process in manufacturing, affecting the precision and yield of display products.
Innovation Solution
A method involving a base substrate with a magnetic layer formed on at least one of its main surfaces within a dummy region, which alleviates drooping through magnetic adsorption forces during evaporation, improving yield and reducing substrate breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the display substrate size is increased to meet user demands, then the display screen area is improved, but the substrate drooping problem occurs during evaporation process
Solution Approach 1:
The patent applies local quality by creating a magnetic layer at specific locations (dummy regions) on the substrate rather than uniformly across the entire substrate. This localized magnetic structure provides targeted support to counteract drooping in critical areas during the evaporation process, allowing large substrate areas to be manufactured with maintained precision.
Solution Approach 2:
The magnetic layer acts as an intermediary between the substrate and the evaporation process. By introducing this intermediate magnetic structure, the patent enables control over substrate behavior during evaporation, mediating the interaction between the large substrate area and the evaporation precision requirements.
2Area of stationary object
If the display substrate size is increased, then the display screen area is improved, but the substrate drooping affects product yield
Solution Approach 1:
By placing magnetic layers specifically in dummy regions rather than across the entire substrate, the patent provides localized support that prevents drooping-induced defects. This approach maintains high yield by addressing precision issues only where they occur during evaporation, while preserving the benefits of large substrate area for higher productivity.
Solution Approach 2:
The magnetic layer serves as an intermediary that protects the evaporation process from substrate drooping, thereby safeguarding product yield. This intermediate structure enables large substrates to be processed successfully, directly improving productivity without sacrificing area.
3Manufacturing precision
If a magnetic layer is formed on the substrate to prevent drooping, then the evaporation precision is improved, but the manufacturing process complexity increases
Solution Approach 1:
The magnetic layer is formed only in dummy regions rather than across the entire substrate, reducing the complexity of the manufacturing process. This localized approach requires less magnetic material and simpler deposition processes compared to full-substrate magnetization, while still achieving the precision improvement needed for evaporation.
Solution Approach 2:
The magnetic layer can be designed as a temporary structure that serves its purpose during evaporation and can be removed or left in the final product depending on requirements. This approach adds minimal permanent complexity to the manufacturing process while achieving the needed precision improvement.
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 magnetic adsorption force stabilizes the substrate during evaporation, enhancing precision and yield while simplifying the manufacturing process by eliminating drooping issues and reducing costs.
Implementation Method 1
the magnetic adsorption layer is located on a side of the second main surface of the base substrate... drooping of the base substrate can be alleviated or eliminated by the magnetic adsorption force
Data Source
AI summary
A method of manufacturing a display substrate and a display substrate motherboard. The method of manufacturing the display substrate includes: providing a base substrate including a first main surface and a second main surface opposite to each other and divided into at least one active region and a dummy region located around the active region; forming a magnetic layer on at least one of the first main surface within the dummy region and the second main surface; and forming an element layer on the first main surface.