Plasma Polymerized Surface Modification for Flexible Glass Carrier Bonding
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Solution Overview
Problem
Flexible glass sheets pose challenges in processing due to increased flexibility, requiring temporary bonding to a carrier to handle them with existing equipment, while preventing covalent bond formation that complicates subsequent separation without damage.
Innovation Solution
A surface modification layer made of plasma polymerized material is applied to the carrier and glass sheet surfaces, reducing surface roughness and enhancing van der Waals bonding to ensure temporary bonding during processing without covalent bond formation, allowing for safe separation post-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the surface roughness of the carrier bonding surface or sheet bonding surface is increased to inhibit covalent bond formation, then covalent bond formation is reduced, but van der Waals bonding forces are significantly reduced to the point that spontaneous bonding does not occur or the bond is too weak to survive processing
Solution Approach 1:
The patent applies plasma treatment to modify the surface chemistry and energy of the bonding surfaces. This changes the surface parameters (surface energy, chemical composition) to enhance van der Waals bonding forces while controlling covalent bond formation, resolving the contradiction between needing strong temporary bonding and preventing permanent bonding.
Solution Approach 2:
The patent introduces a plasma-generated surface layer as an intermediary between the carrier and sheet. This plasma-modified surface acts as a mediator that promotes controlled van der Waals bonding during processing while preventing direct covalent bonding between the bulk materials, enabling temporary bonding that can be cleanly separated afterward.
2Ease of operation
If the flexible glass sheet is temporarily bonded to a carrier to enable handling with existing equipment, then the sheet can be processed with standard equipment, but the bonding must be strong enough to survive processing yet weak enough to allow clean separation without damage
Solution Approach 1:
The patent creates a dynamic bonding system where the bond strength is controlled to be temporary and reversible. The plasma-modified surfaces provide bonding strength that is sufficient for processing operations but can be cleanly separated afterward, transforming the static bonding problem into a dynamic process with controlled bond formation and separation.
Solution Approach 2:
By modifying surface parameters through plasma treatment, the patent achieves optimal bond strength that balances handling requirements with separation needs. The plasma treatment creates surface conditions that promote adequate adhesion for processing while preventing excessive bonding that would damage materials upon separation.
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 plasma polymerized surface modification layer enables temporary bonding of flexible glass sheets to carriers during processing, ensuring the sheets can be safely separated without damage, maintaining the integrity of both the sheet and carrier, and allowing for further use in display configurations.
Implementation Method 1
van der Waals bonding forces may be high enough to permit an initial bond of the sheet to the carrier that will survive processing with the equipment
Implementation Method 2
The surface modification layer includes a plasma polymerized material
Data Source
AI summary
An article includes a carrier including a carrier bonding surface, a sheet including a sheet bonding surface, and a surface modification layer disposed on at least one of the carrier bonding surface and the sheet bonding surface. The surface modification layer includes a plasma polymerized material. The plasma polymerized material planarizes the at least one of the carrier bonding surface and the sheet bonding surface. The carrier bonding surface and the sheet bonding surface are bonded with the surface modification layer so that the carrier is temporarily bonded with the sheet. A method of making an article includes depositing a surface modification layer on at least one of a carrier bonding surface and a sheet bonding surface. The method further includes bonding the carrier bonding surface and the sheet bonding surface with the surface modification layer to temporarily bond the carrier with the sheet.