Hybrid OLED Carrier Singulation via Planar Structure Separation
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Solution Overview
Problem
Conventional methods for singulating hybrid OLED carriers, which include glass and plastic or metal films, are inefficient due to the inability to simultaneously separate different materials using scribe wheels and the high costs and complexity of laser-based separation methods, leading to defects and increased production costs.
Innovation Solution
A method involving the application of a planar structure with predetermined separation locations, which can be made of flexible materials like films or metals, allowing for selective separation and exposure of contact areas without damaging the OLED, using techniques like water jet cutting or laser ablation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a scribe wheel is used to separate glass and plastic films simultaneously, then the separation process is simplified, but the plastics film yields or springs back during scribing resulting in incomplete separation
Solution Approach 1:
The patent divides the separation process into two distinct stages: first separating the glass substrate from the plastic film using a scribe wheel, then removing the plastic film separately using a lifting wheel. This segmentation allows each material to be handled with an appropriate method, preventing the plastic film from springing back during the initial scribing phase.
Solution Approach 2:
The plastic film is pre-structured with separation lines before the scribing process begins. This preliminary action creates predetermined weak points in the plastic film that guide the separation process and prevent uncontrolled springing back during subsequent removal steps.
2Manufacturing precision
If laser methods are used to separate glass and plastic films, then selective separation is achieved, but the equipment cost and maintenance cost increase significantly
Solution Approach 1:
The patent replaces expensive laser separation equipment with conventional mechanical scribe wheels and lifting wheels that are much cheaper to acquire and maintain. While the mechanical tools have limited life, their low cost and simplicity make them economically advantageous compared to expensive laser systems requiring specialized maintenance.
Solution Approach 2:
The patent substitutes optical/laser-based separation with a mechanical two-stage process. Instead of using high-energy laser beams to selectively vaporize materials, the invention uses mechanical scribing followed by mechanical lifting, replacing complex optical systems with simpler mechanical tools.
3Measurement precision
If metal films are trimmed and laminated individually onto OLEDs, then precise positioning is achieved, but particles are incorporated between film and OLED increasing the risk of short circuits
Solution Approach 1:
The patent combines multiple film processing operations into a single continuous lamination step. Instead of trimming and laminating metal films individually for each OLED, the invention laminates the entire metal film structure onto the complete OLED array in one operation, eliminating repeated handling that introduces particles and short circuit risks.
Solution Approach 2:
The metal films are pre-positioned and pre-aligned on the OLED array before the final lamination step. This preliminary action ensures precise positioning is achieved before the films are permanently bonded, eliminating the need for subsequent individual adjustments that would increase contamination risk.
4Manufacturing precision
If glass substrates are scribed at front and rear sides with subsequent breaking, then individual devices are formed, but the process is time-consuming and affects productivity
Solution Approach 1:
The plastic film is pre-structured with separation lines and pre-aligned with the glass substrate before the scribing process. This preliminary preparation ensures that subsequent breaking occurs precisely at the intended locations without requiring multiple adjustment steps, maintaining high singulation accuracy while reducing overall process time.
Solution Approach 2:
The patent segments the singulation process into distinct phases: pre-structuring the plastic film with separation lines, scribing the glass substrate along predetermined paths, and final breaking. This segmentation allows each step to be optimized independently, improving both precision and throughput compared to unoptimized sequential processes.
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 simple and cost-effective singulation of hybrid OLED carriers and exposure of contact areas, reducing production costs and improving the quality of individual OLED devices by allowing selective separation of materials with conventional methods.
Implementation Method 1
using techniques like water jet cutting or laser ablation
Data Source
AI summary
Various embodiments may relate to a method for processing an electronic component. The method includes applying a planar structure provided with predetermined separation locations to the electronic component, and removing a part of the applied planar structure, wherein removing includes separating the planar structure at the predetermined separation locations.