Protective Film Assembly for Display Substrate Defect Reduction
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Solution Overview
Problem
Existing display device manufacturing methods face challenges in achieving a window assembly with improved impact resistance and uniform transparency, while also minimizing defects such as voids and overlaps during the attachment of protective films, which can lead to delamination and damage.
Innovation Solution
A method involving the use of a protective film assembly with monolithic release films attached to each protective film, which are strategically placed and aligned to reduce tolerances and defects, allowing for easier attachment and removal without excessive release force, thereby minimizing substrate damage and equipment size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple protective films are used to cover the substrate, then the impact resistance and surface protection are improved, but the release force during removal increases causing substrate separation and damage
Solution Approach 1:
The protective film assembly is divided into multiple individual protective films (first protective film, second protective film, etc.) that can be separately attached and removed. Each protective film is independently positioned and secured to the substrate, allowing controlled removal without excessive force that would cause substrate damage or separation.
2Manufacturing precision
If protective films are attached to the substrate, then surface protection and uniform transparency are improved, but defects such as voids and overlaps occur leading to delamination
Solution Approach 1:
Positioning marks are pre-formed on the substrate before attaching the protective films. These marks guide the precise alignment of each protective film, ensuring proper positioning and preventing defects such as voids, overlaps, and delamination during the attachment process.
Solution Approach 2:
A release film is used as an intermediary layer between the protective films and the substrate during the attachment process. The release film facilitates controlled positioning and removal, reducing the risk of defects and enabling precise alignment without direct adhesive contact that could cause delamination.
3Ease of operation
If a large-sized equipment is used to peel protective films, then complete removal is achieved, but the equipment size and complexity increase
Solution Approach 1:
The protective films are divided into multiple smaller individual films rather than one large film. This segmentation allows each film to be removed separately using simpler, smaller equipment, reducing the overall equipment size and complexity while still achieving complete removal of all protective films from the substrate.
Data Source
AI summary
A manufacturing method of a display device includes: forming a window assembly; forming a display module; and attaching the window assembly to the display module. The forming of window assembly includes: preparing a substrate; placing a first protective film assembly including a plurality of first protective films and a first release film on an upper surface of the substrate; removing the first release film from the first protective films; and attaching the first protective films to the upper surface of the substrate.