UV Reflective Layer for Laser Substrate Stripping

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Solution Overview

Problem

The existing display panel manufacturing process faces challenges in stripping the rigid substrate using laser lift-off technique, where low-energy lasers fail to remove the substrate successfully, and high-energy lasers damage the film structure, affecting flexibility and reliability.

Innovation Solution

A display panel design incorporating an ultraviolet reflective layer with a pair of reflective layers having different refractive indices, along with a supplementary substrate, is used to control laser energy and prevent damage during substrate stripping, ensuring precise laser wavelength reflection and absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high-energy laser is used for substrate stripping, then the rigid substrate can be removed successfully, but the film structure is damaged affecting flexibility and reliability

Engineering Contradiction:
Improvesubstrate stripping efficiencyVSAvoidfilm structure integrity
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The patent introduces an ultraviolet reflective layer as an intermediary component between the substrate and the thin film transistor array. This reflective layer mediates the laser stripping process by reflecting excess ultraviolet light away from the film structure, allowing high-energy laser to successfully remove the substrate while protecting the film from damage. The reflective layer acts as a buffer that manages laser energy distribution.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent converts the potentially harmful effect of high-energy laser radiation on the film structure into a beneficial process. By designing the ultraviolet reflective layer with specific refractive index characteristics, the harmful excess laser energy is reflected back to assist in substrate removal while the film structure remains protected. The harmful high-energy laser is thus transformed into a useful stripping tool when properly managed by the reflective layer.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If low-energy laser is used for substrate stripping, then the film structure is protected, but the substrate cannot be removed successfully

Engineering Contradiction:
Improvefilm structure integrityVSAvoidsubstrate stripping efficiency
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The ultraviolet reflective layer serves as a mediator that enables the use of low-energy or moderate-energy lasers for substrate stripping. By reflecting excess ultraviolet light, it concentrates the necessary energy at the substrate interface while preventing energy dissipation that would require higher initial laser power. This intermediary layer makes efficient substrate removal possible with controlled laser energy.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the optical parameters of the system by introducing a layer with specific refractive index properties (different from both the substrate and the film layers). This parameter change in the optical path allows for more efficient energy transfer during laser stripping, enabling successful substrate removal with lower laser energy than would be required without the reflective layer.

Inventive Principle:
Principle #35Parameter changes

3Productivity

If ultraviolet laser is used for substrate stripping, then the substrate can be removed, but excess laser light damages the display panel structure

Engineering Contradiction:
Improvesubstrate stripping efficiencyVSAvoidlaser light damage to panel structure
Core Design Contradiction:
ProductivityVSObject-affected harmful factors

Solution Approach 1:

The ultraviolet reflective layer acts as a protective intermediary that intercepts and reflects excess ultraviolet laser light before it can reach and damage the thin film transistor array and other sensitive components. This intermediary layer allows the ultraviolet laser to successfully strip the substrate while preventing the harmful side effect of laser-induced damage to the display panel structure.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent converts the harmful excess ultraviolet light that would normally damage the panel into a beneficial reflected beam. By positioning the reflective layer strategically, the excess laser energy that would cause damage is instead reflected back to assist in the substrate stripping process or safely directed away from sensitive components, turning a harmful factor into a useful or neutral element.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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 ultraviolet reflective layer effectively reflects excess laser light, protecting the display panel structure and maintaining its flexibility and reliability by optimizing the laser energy usage during the stripping process.

Implementation Method 1

an ultraviolet reflective layer for reflecting excess laser light is disposed between the substrate and the thin film transistor array

Methodology Applied
Scientific EffectReflection: Reflection

Implementation Method 2

an ultraviolet reflective layer for reflecting excess laser light is disposed between the substrate and the thin film transistor array so as to avoid the problem that the laser damages the structure of the display panel during the rigid substrate stripping process

Methodology Applied
Scientific EffectAbsorption (EM radiation): Absorption (EM radiation)

Data Source

PatentUS11139358B2Display panel and manufacturing method thereof
Publication Date: 2021.10.05 WUHAN CHINA STAR OPTOELECTRONICS SEMICONDUCTOR DISPLAY TECHNOLOGY CO LTD
  • US11139358B2 patent drawing
  • US11139358B2 patent drawing
  • US11139358B2 patent drawing

AI summary

A display panel and a manufacturing method for the display panel are provided. The display panel includes a substrate. An ultraviolet reflective layer is disposed on the substrate. A thin film transistor array is disposed on the ultraviolet reflective layer. A light emitting device is disposed on the thin film transistor. An encapsulation layer is disposed on the light emitting device. The ultraviolet reflective layer includes at least one pair of a first reflective layer and a second reflective layer stacked on each other. The refractive indexes of the first reflective layer and the second reflective layer are different.