Plastic Substrate Separation via Island Lubricators
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Solution Overview
Problem
The challenge in manufacturing electronic apparatuses with plastic substrates is to maintain precise positioning during device formation without damaging the substrate and ensure easy separation from the manufacturing stage without damaging the substrate or devices.
Innovation Solution
A method involving a stage with island-shaped separation lubricators and an anti-peeling member is used, where the adhesive force between the lubricators and the stage is greater than between the lubricators and the substrate, allowing for precise attachment and easy separation of the plastic substrate, utilizing materials like silicon oxide, silicon nitride, and oxides for the lubricators and anti-peeling member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the plastic substrate is disposed directly on the stage without separation lubricators, then the substrate maintains stable positioning during device formation, but the substrate cannot be easily separated from the stage without damage
Solution Approach 1:
The stage surface is segmented into multiple regions: adhesive regions that bond to the plastic substrate and non-adhesive regions (island-shaped separation lubricators) that prevent bonding. This segmentation allows the substrate to be securely held during manufacturing while enabling clean separation at designated locations without damaging the substrate or devices.
Solution Approach 2:
Separation lubricators act as intermediary elements between the stage and the plastic substrate. These lubricators create a controlled interface that prevents direct adhesion between the substrate and stage, facilitating easy separation while maintaining substrate integrity through the use of materials with appropriate adhesive properties.
2Manufacturing precision
If the adhesive force between the substrate and stage is increased to prevent displacement during device formation, then positioning precision is improved, but separation becomes difficult and may damage the substrate or devices
Solution Approach 1:
The stage surface exhibits local quality variations through the distribution of adhesive and non-adhesive regions. The adhesive regions provide strong bonding for precise positioning during device formation, while the non-adhesive island-shaped separation lubricators enable easy separation. This local differentiation of adhesive properties resolves the contradiction between secure positioning and easy 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
This method ensures the plastic substrate and devices are protected during formation and easily separated, increasing manufacturing yield and reducing damage, while optimizing material usage and manufacturing costs.
Implementation Method 1
An adhesive force between the island-shaped separation lubricators and the stage may be greater than an adhesive force between the island-shaped separation lubricators and the plastic substrate
Implementation Method 2
An adhesive force between the anti-peeling member and the plastic substrate may be greater than an adhesive force between the stage and the plastic substrate
Data Source
AI summary
A method of manufacturing an electronic apparatus including a plastic substrate, which can facilitate in separating the electronic apparatus including the plastic substrate from a stage, an electronic apparatus manufactured using the method, and an apparatus including the stage for use in the method. The method includes: preparing a stage on which a plurality of island-shaped separation lubricators are arranged; disposing the plastic substrate on the stage; forming a device on the plastic substrate; and separating the plastic substrate from the stage.