Self-Adaptive Grinding Disc for Full Substrate Contact Cleaning
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Solution Overview
Problem
Existing grinding and cleaning processes in display panel manufacturing suffer from low efficiency due to non-parallel alignment between the grinding disc and the substrate, leading to incomplete cleaning and reduced production rates, with existing solutions failing to maintain stability over time.
Innovation Solution
A grinding disc with a thickness self-adaptive layer that deforms based on pressure, combined with a grinding plate and optionally a metal pad and flange, ensures complete contact with the substrate surface, enhancing cleaning effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If a traditional rigid grinding disc is used, then the structure is simple and easy to manufacture, but the contact area with the substrate is insufficient (only 30% effective cleaning area) due to non-parallel alignment
Solution Approach 1:
The grinding disc incorporates a soft layer that enables dynamic adaptation to the substrate surface. The soft layer deforms under pressure to conform to non-parallel surfaces, transforming the rigid structure into a dynamically adaptable one that maintains contact across the entire substrate area.
Solution Approach 2:
The patent changes the physical parameter of the grinding disc by introducing a soft layer with specific mechanical properties (softness, deformability). This parameter change allows the grinding disc to transition from a rigid, fixed-geometry structure to one that can elastically deform to match the substrate surface geometry.
2Reliability
If manual adjustment of the grinding disc is performed to improve alignment, then cleaning effectiveness improves, but production time increases due to repeated adjustments
Solution Approach 1:
The soft layer enables the grinding disc to self-adjust to the substrate surface automatically during operation. The elastic deformation occurs naturally under operating pressure, eliminating the need for manual intervention or complex adjustment mechanisms, thus maintaining high cleaning effectiveness without time loss.
Solution Approach 2:
The soft layer is pre-configured with deformable properties that enable automatic adaptation before the actual grinding process begins. This preliminary design feature ensures that the grinding disc is already adapted to the substrate surface geometry when operation starts, avoiding subsequent adjustments.
3Reliability
If automatic optical monitoring is added to control dirt before LLO, then product quality improves, but input product to LLO decreases and utilization rate is seriously affected
Solution Approach 1:
The soft layer performs preliminary cleaning action by ensuring complete contact between the grinding disc and substrate surface. This preliminary cleaning effectiveness prevents dirt from entering the LLO equipment, eliminating the need for subsequent optical monitoring and product rejection, thus maintaining both quality and productivity.
4Ease of manufacture
If the grinding disc is made non-parallel to the substrate, then manufacturing is simpler, but long term grinding causes deviation and stable effect cannot be kept
Solution Approach 1:
The soft layer provides dynamic stability by continuously adapting to substrate variations during long-term grinding operations. This dynamic adaptation compensates for any initial misalignment or wear, maintaining consistent cleaning effectiveness over time without requiring precise initial manufacturing alignment.
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 self-adaptive design increases the contact area between the grinding disc and substrate, overcoming blind spots and improving cleaning efficiency to achieve a 100% effective cleaning area, thereby enhancing production yield.
Implementation Method 1
a thickness self-adaptive layer disposed on the base layer, wherein the thickness self-adaptive layer is configured to deform based on pressure
Implementation Method 2
The grinding plate is a magnetic metal material, and the metal pad and the grinding plate are attached and fixed to each other magnetically
Data Source
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AI summary
The present application provides a grinding disc and a substrate cleaning device. The grinding disc includes a thickness self-adaptive layer and a base layer and a grinding plate fixed on two opposite surfaces of the thickness self-adaptive layer respectively. The base layer is connected to the grinding head. The grinding plate contacts a product to grind and clean the product. The thickness self-adaptive layer can deform based on a pressure applied by the grinding disc to the product to be cleaned such that the grinding disc completely contacts a surface of the product to be cleaned to make a cleaning area of the grinding disc achieve 100%, which can improve a cleaning rate of the product.