Multilayer Protection Film for Etching Display Substrates
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Solution Overview
Problem
During the etching process of display apparatus manufacturing, the penetration of etchant molecules into protection films can damage touch screen panels, posing a challenge in protecting the panels while reducing substrate thickness for lightweight and minimized display devices.
Innovation Solution
A multilayer protection film with varying penetration hole sizes and thicknesses is applied to the touch screen panel, where the first protection film is exposed during etching, and subsequent films have progressively smaller holes and thicker layers, controlling etchant penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-layer protection film with uniform penetration holes is used, then the structure is simple, but the etching process cannot effectively protect the touch screen panel from etchant penetration
Solution Approach 1:
The protection film is divided into multiple layers (first protection film, second protection film, third protection film) with progressively smaller penetration holes. This segmentation allows each layer to perform a specific function in the etching process, with the outer layers allowing controlled etchant passage and inner layers providing final protection, thereby resolving the contradiction between protection effectiveness and structural simplicity.
Solution Approach 2:
Different regions of the protection film structure have different properties: the first protection film has larger penetration holes for initial etching access, while subsequent layers have progressively smaller holes for refined control. This local differentiation of properties enables the system to achieve both effective protection and controlled etching efficiency.
2Weight of stationary object
If substrate thickness is reduced for lightweight design, then the display apparatus becomes lighter and more minimized, but the substrate becomes more vulnerable to etchant damage
Solution Approach 1:
The multilayer protection film structure is applied beforehand to the substrate before etching occurs. The progressively smaller penetration holes in successive layers create a cushioning effect that gradually reduces etchant penetration, protecting the thinned substrate from direct exposure to harsh etchants while allowing the etching process to proceed effectively.
3Reliability
If penetration holes in protection films are made smaller to prevent etchant penetration, then protection improves, but etching efficiency decreases
Solution Approach 1:
The etching process is segmented into stages corresponding to different protection film layers. The first layer with larger holes enables efficient initial etching, while subsequent layers with smaller holes provide progressive protection. This segmentation allows the system to achieve both high etching efficiency in early stages and effective protection in later stages, resolving the contradiction between protection and efficiency.
Solution Approach 2:
The multilayer structure creates a periodic pattern of penetration hole sizes that corresponds to the etching process progression. This periodic variation in hole size allows the system to alternate between phases of higher etching efficiency (larger holes) and higher protection (smaller holes), optimizing both productivity and reliability throughout the etching process.
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 effectively protects the touch screen panel during etching, improving etching process efficiency and achieving reduced substrate thickness for lightweight and minimized display apparatus.
Implementation Method 1
The protection films have penetration holes, an average area of the penetration holes of each of the protection films in a plan view being equal to or smaller than a size of molecules in the etchant
Data Source
AI summary
A method of manufacturing a display apparatus includes providing a display panel including two substrates facing each other and a display device disposed between the two substrates; providing a touch screen panel attached onto an outer side surface of one of the two substrates; attaching a multilayer protection film including a plurality of films having acid resistance onto the touch screen panel; etching the other of the two substrates; and removing the multilayer protection film. The protection films have penetration holes, each of the protection films having a different average area of the penetration holes in a plan view.