Sn-Diffused Glass Substrate for Film Adhesion and Fine Patterning
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Solution Overview
Problem
The interaction between films and glass substrates in flat panel displays is insufficient, leading to adhesion issues, which can cause production yield deterioration and increased manufacturing costs, especially as displays become higher in definition and require finer pattern forming.
Innovation Solution
A glass substrate with a specific range of surface layer diffusion Sn atom concentration, between 2.0×1018 atomic/cm3 and 1.4×1019 atomic/cm3, enhances adhesion to films by diffusing bivalent Sn atoms from the glass substrate surface, improving productivity and enabling finer pattern formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin film is formed on a glass substrate to improve display characteristics, then the film can provide necessary functional properties, but the adhesion between the film and glass substrate becomes insufficient causing local separation
Solution Approach 1:
The invention changes the chemical composition parameters of the glass substrate by controlling the Sn atom concentration in the surface layer to be 2.0×10^18 to 1.4×10^19 atomic/cm³. This parameter modification creates sufficient adhesion sites for resin films, preventing local separation and improving both adhesion reliability and production yield simultaneously
Solution Approach 2:
The Sn atoms in the glass substrate surface layer act as an intermediary between the glass substrate and the resin film. These Sn atoms provide adhesion sites that facilitate strong bonding, eliminating the need for additional adhesion promotion layers or complex surface treatments
2Manufacturing precision
If higher definition displays are developed requiring finer pattern forming, then display quality improves, but the burden on manufacturing management and cost increases
Solution Approach 1:
By optimizing the Sn atom concentration parameter in the glass substrate surface layer, the invention enables finer pattern formation with improved adhesion. This single parameter change allows high-definition displays to be manufactured with better pattern precision while reducing manufacturing complexity through a straightforward production process
3Ease of manufacture
If conventional glass substrates are used without surface treatment, then manufacturing process is simple, but adhesion to films is insufficient causing local separation
Solution Approach 1:
The invention achieves improved adhesion through a simple parameter change in glass substrate composition (controlling Sn atom concentration in the surface layer), rather than through complex surface treatments. This maintains ease of manufacture while significantly improving adhesion reliability, preventing film separation
Solution Approach 2:
The glass substrate itself provides the adhesion function through its inherent Sn atom content in the surface layer, eliminating the need for separate adhesion promotion treatments. The substrate serves its own adhesion needs, simplifying the manufacturing process while ensuring reliable film bonding
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 enhanced adhesion between the glass substrate and films allows for finer pattern formation while reducing fluorescence emission issues that can affect device production processes.
Implementation Method 1
a glass substrate in which an Sn concentration in at least one main surface is not lower than a specific range is high in adhesion to a film formed on the surface of the glass substrate
Data Source
AI summary
The present invention relates to a glass substrate including a pair of main surfaces and an end surface, and having a surface layer diffusion Sn atom concentration of 2.0×1018 atomic/cm3 or more and 1.4×1019 atomic/cm3 or less in at least one of the main surfaces, the surface layer diffusion Sn atom concentration being obtained by subtracting an Sn atom concentration of an inside of the glass substrate from an Sn atom concentration of a surface layer of the glass substrate, in which the Sn atom concentration of a surface layer of the glass substrate is defined as an Sn atom concentration at a depth of 0.1 to 0.3 μm from the main surface and the Sn atom concentration of an inside of the glass substrate is defined as an Sn atom concentration at a depth of 9.0 to 9.2 μm from the main surface.