Method of detaching display module and method of manufacturing display module

Patent metadata

Field	Value
Publication number	US-10014494-B2
Application number	US-201715704150-A
Country	US
Kind code	B2
Filing date	Sep 14, 2017
Priority date	Oct 19, 2016
Publication date	Jul 3, 2018
Grant date	Jul 3, 2018

Abstract

Provided is a method of detaching a display module. The method of detaching the display module includes providing a carrier substrate, forming a display module, which is divided into a first area and a second area, on the carrier substrate, disposing a protective film covering the first area and exposing the second area on the display module, performing a first detaching process of detaching the second area from the carrier substrate by using a first detaching unit, and performing a second detaching process of detaching the protective film and the display module from the carrier substrate by using a second detaching unit.

First claim

What is claimed is:

1. A method of detaching a display module, comprising:
providing a carrier substrate;
forming a display module, which is divided into a first area and a second area, on the carrier substrate;
disposing a protective film covering the first area and exposing the second area on the display module;
performing a first detaching process of detaching the second area from the carrier substrate by using a first detaching unit; and
performing a second detaching process of detaching the protective film and the display module from the carrier substrate by using a second detaching unit.

2. The method of claim 1 , wherein the second detaching process is performed after the first detaching process is performed.

3. The method of claim 1 , wherein, in the first detaching process, the first detaching unit comes into direct contact with the display module to detach the second area of the display module from the carrier substrate, and
in the second detaching process, the second detaching unit comes into direct contact with the protective film to detach the display module and the protective film from the carrier substrate.

4. The method of claim 1 , wherein a boundary between the first area and the second area extends in a first direction, and
in the first detaching process, the second area extending in the first direction is detached from the carrier substrate.

5. The method of claim 1 , wherein the display module has a plurality of vertexes, and
in the disposing of the protective film, the protective film is disposed so that the protective film does not cover only one vertex of the plurality of vertexes.

6. The method of claim 5 , wherein, in the first detaching process, the first detaching unit detaches the one vertex from the carrier substrate.

7. The method of claim 6 , further comprising:
inserting a cutting member between the second area of the display module and the carrier substrate before the second detaching process; and
moving the cutting member in a first direction.

8. The method of claim 1 , wherein the first detaching unit comprises a first absorption pad, and the second detaching unit comprises a second absorption pad, and
the first detaching process is performed by the first absorption pad, and the second detaching process is performed by the second absorption pad.

9. The method of claim 8 , wherein absorption force of the first absorption pad in the first detaching process is greater than that of the second absorption pad in the second detaching process.

10. The method of claim 8 , wherein the first absorption pad comprises a plurality of first absorption pads, and the second area is detached from the carrier substrate by the plurality of first absorption pads.

11. The method of claim I, wherein the first detaching unit comprises a support and an adhesive tape wound around the support, and
in the first detaching process, the second area adheres to the adhesive tape and is detached from the carrier substrate.

12. The method of claim 1 , wherein the second detaching unit comprises a plurality of absorption pads, and
in the second detaching process, the plurality of absorption pads move at the same time in a direction that is away from the carrier substrate to detach the protective film and the display module from the carrier substrate.

13. The method of claim 1 , wherein the second detaching unit comprises a plurality of absorption pads, and
in the second detaching process, the protective film and the display module are detached from the carrier substrate in order from the absorption pads, which are adjacent to the first detaching unit, of the plurality of absorption pads.

14. The method of claim 1 , wherein the forming of the display module comprises:
providing a base layer on the carrier substrate;
forming a circuit layer on the base layer; and
forming a light emitting device layer on the circuit layer,
wherein all the base layer, the circuit layer, and the light emitting device layer are disposed within the first area, and the base layer is disposed within the second area.

15. The method of claim 1 , further comprising forming a sacrificial layer on the carrier substrate before the forming of the display module.

16. A method of manufacturing a display module, comprising:
providing a carrier substrate;
forming a base layer comprising an effective area and a dummy area on the carrier substrate;
forming a circuit layer on the effective area;
forming a light emitting device layer on the circuit layer;
forming an encapsulation layer covering the light emitting device layer and the circuit layer on the light emitting device layer;
disposing a protective film covering the effective area and exposing at least a portion of the dummy area on the encapsulation layer;
performing a detaching process of detaching the base layer, the circuit layer, the light emitting device layer, the encapsulation layer, and the protective film from the carrier substrate; and
cutting a boundary between the dummy area and the effective area to remove the dummy area.

17. The method of claim 16 , wherein the detaching process comprises:
performing a first detaching process of detaching the at least a portion of the dummy area of the base layer, which is exposed by the protective film, from the carrier substrate; and
performing a second detaching process of detaching the base layer covered by the protective film from the carrier substrate after the first detaching process.

18. The method of claim 17 , wherein the detaching process further comprises performing an intermediate detaching process of detaching the other portion of the dummy area, which is not detached from the carrier substrate before the second detaching process, from the carrier substrate after the first detaching process.

19. The method of claim 16 , further comprising forming a sacrificial layer on the carrier substrate before the forming of the base layer on the carrier substrate.

20. The method of claim 16 , further comprising detaching the protective film from the base layer, the circuit layer, the light emitting device layer, and the encapsulation layer before the removing of the dummy area.

Assignees

• Samsung Display Co Ltd

Inventors

• Yeo Gilhwan
• Lee Min-Woo
• Moon Seungjun

Classifications

• H10P72/10

  using carriers specially adapted therefor, e.g. front opening unified pods [FOUP] · CPC title

• H10P72/0442 Primary

  Apparatus for placing on an insulating substrate, e.g. tape · CPC title

• H01L51/56 Primary

  Electricity · mapped topic

• H01L51/003

  Electricity · mapped topic

• H01L2227/326

  Electricity · mapped topic