Moisture-Absorbing Display Panel for Laser-Free Substrate Separation

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Solution Overview

Problem

Existing display panels face challenges in easily separating from carrier substrates without additional processes like laser irradiation, and there is a need to control the coupling force between these substrates effectively.

Innovation Solution

A display panel design incorporating a moisture absorption material, such as metal, metal oxide, or silicon oxide, is used to form a porous layer that reduces the coupling force, allowing easy separation from the carrier substrate by applying opposite forces without laser treatment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a base substrate is provided to a carrier substrate through depositing and patterning, then the display device can be manufactured, but the separation process becomes complex requiring additional processes like laser irradiation

Engineering Contradiction:

Improvedisplay device manufacturingVSAvoidseparation process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A release layer is formed between the base substrate and carrier substrate before the display device is manufactured. This preliminary action enables easy separation later without requiring complex laser irradiation processes, while still allowing complete manufacturing of the display device.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The release layer acts as an intermediary between the base substrate and carrier substrate. This intermediate layer facilitates the separation process by providing a controlled interface that reduces adhesion, allowing the base substrate to be separated from the carrier substrate without damaging the manufactured display device.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If the coupling force between carrier substrate and base substrate is strong, then the display panel is stable during manufacturing, but separation becomes difficult without additional processes

Engineering Contradiction:

Improvedisplay panel stabilityVSAvoidseparation process

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The release layer is pre-formed with specific material properties that provide controlled adhesion. During manufacturing, the layer maintains sufficient coupling for stability, but its preliminary preparation enables easy separation later without requiring additional processes like laser irradiation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The release layer's material parameters are selected to provide different adhesion characteristics at different stages. The layer maintains strong coupling during manufacturing for stability, but allows easy separation when needed by changing the effective adhesion parameter through the inherent properties of the release layer material.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If laser irradiation is used to separate the base substrate from the carrier substrate, then separation can be achieved, but thermal damage may occur to the display device

Engineering Contradiction:

Improveseparation capabilityVSAvoidthermal damage

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The release layer serves as a mediator that enables separation through mechanical means rather than thermal processes. By providing a low-adhesion interface, the release layer allows separation through simple peeling or delamination without requiring laser irradiation, thereby avoiding thermal damage to the display device.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention replaces the thermal-mechanical separation method (laser irradiation) with a purely mechanical separation method. The release layer enables separation through mechanical peeling or delamination forces, substituting the need for thermal energy input and eliminating the associated thermal damage risks.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method enables efficient separation of the display panel from the carrier substrate without thermal damage, reducing the need for additional processes and maintaining panel integrity.

Implementation Method 1

a moisture absorption layer between the carrier substrate and the base part, and including a moisture absorption material... Injecting moisture into the moisture absorption layer to deform the moisture absorption layer

Methodology Applied

Scientific EffectMoisture absorption: Absorption (physical)

Implementation Method 2

Injecting moisture into the moisture absorption layer may cause the moisture absorption layer to expand in volume due to the injected moisture

Methodology Applied

Scientific EffectVolume expansion due to moisture absorption: Absorption (physical)

Data Source

PatentUS12453240B2Display panel, stacked substrate including the same, and method of manufacturing the display panel

Publication Date: 2025.10.21 SAMSUNG DISPLAY CO LTD

AI summary

A display panel includes a base substrate having a first surface and a second surface opposing each other, a pixel part located on the first surface, and including a plurality of pixels, and a remaining part on the second surface to cover at least a portion of the second surface, and including a moisture absorption material having a moisture absorption property.