Supporting Substrate for Thin Glass Display Panel Manufacturing
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Solution Overview
Problem
The challenge in display panel manufacturing is to reduce the thickness and weight of glass substrates while preventing bending, drooping, and curving issues, which are exacerbated in large-scale substrates and can be damaged during handling, and existing methods like etching increase manufacturing costs or fail to maintain substrate integrity.
Innovation Solution
A manufacturing method involving thicker supporting substrates made of glass, ranging from 0.5 mm to 1 mm, which support thinner glass substrates (0.05 mm to 0.2 mm) during the cell-formation and packaging processes, using vacuum bonding, adhesive bonding, plasma processing, and air injection to maintain structural integrity and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the glass substrate thickness is reduced to decrease weight and improve thinness, then the weight and thickness are improved, but the glass substrate becomes easily bent and may have drooping or curving issues during manufacturing
Solution Approach 1:
The patent applies preliminary action by pre-configuring the glass substrate on a supporting substrate before the cell-formation process. The supporting substrate provides temporary mechanical support to prevent bending and curving during manufacturing operations. This preliminary support structure is removed after the display panel is assembled, allowing the thin glass substrate to maintain its flatness throughout the manufacturing process without requiring permanent reinforcement.
2Weight of moving object
If etching process is used to reduce glass substrate thickness and weight, then weight and thickness are reduced, but manufacturing cost increases greatly if etching fails
Solution Approach 1:
The patent employs the disposable principle by using a temporary supporting substrate that is discarded after serving its purpose. The supporting substrate provides necessary mechanical support during manufacturing but is removed and discarded after the display panel is assembled. This approach avoids the high cost and complexity of permanent glass substrate modifications like etching, while still enabling the use of thin glass substrates.
3Length of moving object
If thinner glass substrate is adopted to reduce thickness and weight, then thickness and weight are reduced, but the substrate may be bent during transmission and handling
Solution Approach 1:
The patent applies preliminary action by pre-configuring the glass substrate on a supporting substrate before handling and manufacturing operations. The supporting substrate acts as a temporary reinforcement that prevents bending and damage during transmission and processing. After the display panel is assembled, the supporting substrate is removed, leaving the thin glass substrate intact and functional.
4Strength
If vacuum bonding or adhesive bonding is used to bond supporting substrate with glass substrate, then bonding strength is improved, but process complexity increases
Solution Approach 1:
The patent applies mechanics substitution by replacing traditional mechanical bonding methods with vacuum bonding or adhesive bonding. Instead of using mechanical fasteners or complex mechanical joining systems, the invention uses vacuum pressure or chemical adhesion to bond the supporting substrate to the glass substrate. This substitution simplifies the overall bonding process while maintaining strong attachment during the manufacturing operations.
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 effectively prevents bending and curving of thinner glass substrates, enhances manufacturing precision and convenience, and ensures a flat, smooth surface for display panels by using thicker supporting substrates to stabilize the thinner glass substrates throughout the manufacturing process.
Implementation Method 1
configuring the glass substrate on the supporting substrate... the supporting substrate has a thickness in a range from 0.5 mm to 1 mm, and the thickness of the glass substrate is in a range from 0.05 mm to 0.2 mm
Implementation Method 2
configuring the supporting substrate and the glass substrates to contact with each other so as to bond the supporting substrate with the glass substrates under vacuum condition
Implementation Method 3
bonding the supporting substrate and the glass substrate together via adhesive
Implementation Method 4
adopting fluorine to conduct a plasma process on the supporting substrate
Data Source
AI summary
The present disclosure relates to a manufacturing method of display panels. The method includes providing at least two glass substrate having a predetermined dimension, configuring the glass substrate to be spaced apart from a supporting substrate, configuring a bonding area on the glass substrate, conducting a cell-formation process or a package process of the display panel, and stripping the supporting substrate. In this way, the thicker supporting substrate is configured to support the glass substrate so as to avoid two ends of the thinner glass substrate from dropping and curing, which enhances the convenience and the precision of the manufacturing process of the display panel.