Sacrificial Layer Laser Separation for High-Temperature Display Substrates
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Solution Overview
Problem
Existing manufacturing methods for display substrates face challenges in efficiently separating flexible display substrates from carrier substrates at high temperatures without damaging the substrates, as traditional sacrificial layers are vulnerable to high temperatures and have low energy absorption efficiency.
Innovation Solution
A method involving a mixture of organic material, inorganic particles, and solvent is applied to a carrier substrate, forming a sacrificial layer with increased surface roughness and transparency, which is then separated using a laser, allowing for efficient separation of the display substrate from the carrier substrate even at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional sacrificial layer is used for separation, then the separation process is simple, but the sacrificial layer is damaged at high temperatures and has low energy absorption efficiency
Solution Approach 1:
The patent applies composite materials by combining organic material (polymer matrix) with inorganic particles (metal oxides or carbides) to create a sacrificial layer that exhibits both thermal stability and high energy absorption efficiency. The inorganic particles dispersed in the organic matrix provide laser absorption capability while the organic binder maintains structural integrity at high temperatures, resolving the contradiction between stability and energy absorption.
Solution Approach 2:
The patent changes the physical and chemical parameters of the sacrificial layer by selecting specific organic materials with high glass transition temperatures and inorganic particles with appropriate laser absorption coefficients. By adjusting the composition ratios and particle sizes, the sacrificial layer achieves optimal performance at high temperatures while maintaining high energy absorption efficiency for laser-induced separation.
2Manufacturing precision
If the sacrificial layer is made transparent for better optical properties, then the display substrate quality improves, but the energy absorption efficiency for laser separation decreases
Solution Approach 1:
The patent applies local quality by creating a sacrificial layer with spatially varying properties: the inorganic particles are distributed throughout the organic matrix to provide localized laser absorption centers, while the overall layer maintains the transparency and surface quality required for display substrate manufacturing. This allows different regions of the sacrificial layer to serve different functions - absorption centers for energy uptake and transparent matrix for optical quality.
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 enables effective separation of the display substrate from the carrier substrate at temperatures above 400°C, maintaining the properties of the sacrificial layer and preventing damage, while enhancing energy absorption efficiency for smooth separation.
Implementation Method 1
separating the barrier layer and the display substrate from the carrier substrate by applying a laser to the sacrificial layer
Implementation Method 2
The organic material may include one or more of poly-para-xylene or poly dimethyl diphenyl siloxane resin
Data Source
AI summary
A manufacturing method of a display substrate, including preparing a carrier substrate; preparing a mixture of an organic material, an inorganic particle, and solvent; coating the mixture on the carrier substrate; forming a sacrificial layer including the inorganic particle in the organic material by curing the mixture; forming a barrier layer on the sacrificial layer; forming a display substrate on the barrier layer; and separating the barrier layer and the display substrate from the carrier substrate by applying a laser to the sacrificial layer.