Patent ID: 12208470

DETAILED DESCRIPTION

In the present disclosure, it will be understood that when an element or layer is referred to as being “on”, “connected to” or “coupled to” another element or layer, it can be directly on, connected or coupled to the other element or layer or intervening elements or layers may be present.

Like numerals may refer to like elements throughout the specification. In the drawings, the thickness, ratio, and dimension of components may be exaggerated for effective description of the technical content.

As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another. Thus, a first element, component region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present disclosure. As used herein, description of a singular element may be applied to a plurality of the same element, unless the context clearly indicates otherwise.

Spatially relative terms, such as “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

It should be understood that the terms “comprise”, “have”, or “include are intended to specify the presence of stated features, integers, steps, operations, elements, components, or combinations thereof in the disclosure, but do not necessarily preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or combinations thereof.

Hereinafter, the present disclosure will be explained in detail with reference to the accompanying drawings.

FIG.1is a perspective view showing a substrate-cutting apparatus according, to an embodiment of the present disclosure.

Referring toFIG.1, the substrate-cutting apparatus may include a stage SG supporting a plurality of substrates ST, an adhesive layer AY, a laser module LR configured to cut the substrates ST, and a controller CT that may control the laser module LR.

The stage SG may have a quadrangular shape and may support the substrates ST. The stage SG may include a material with sufficient strength to support the substrates ST.

Each of the substrates ST is substantially parallel to a plane defined by a first direction DR1and a second direction DR2. For example, the directions DR1and DR2may span a horizontal plane. A third direction DR3may be defined as a direction normal to the plane of the substrates ST, or a vertical direction. The third direction DR3may also be referred to as a thickness direction. In the following descriptions, a expression “when viewed in a plan view” or “in a plane” may refer to a view in the third direction DR3; for example, a top-down view. Hereinafter, front (or upper) and rear (or lower) surfaces of each layer or each unit are distinguished from each other by the third direction DR3. However, directions indicated by the first, second, and third directions DR1, DR2, and DR3are relative to each other, and thus, the directions indicated by the first, second, and third directions DR1, DR2, and DR3may be changed to other directions, e.g., opposite directions.

According to an embodiment of the present disclosure, the substrates ST may be stacked one on another. Each of the substrates ST may include a plurality of active areas AA and a non-active area NAA adjacent to the active areas AA. The substrates ST may be aligned with each other in the third vertical) direction DR3. In particular, the active areas AA of two substrates adjacent to each other among the substrates ST may substantially overlap each other and may correspond to each other in the third direction DR3.

The active areas AA of each of the substrates ST may be applied to an actual display device, and the non-active area NAA may be a residual area generated after a cutting process. The active areas AA may be spaced apart from each other when viewed in a plane and may be surrounded by the non-active area NAA. The active areas AA defined in each of the substrates ST may correspond to a plurality of windows including a glass, respectively.

However, the present disclosure is not necessarily limited thereto, and the active areas AA defined in each of the substrates ST may mean a display module, or a single base substrate included in the display module. The display module may include at least one of: a display panel displaying an image and an input sensing unit sensing an external input.

In the following descriptions, a boundary line between the active areas AA and the non-active area NAA will be described as a cutting line CL. For example, as a laser beam, which is output from a laser module LR described later, is irradiated onto the cutting line CL, the active areas AA of each of the substrates ST may be separated from each other.

Hereinafter, the substrates ST will be described as including first, second, third, fourth, fifth, and sixth substrates ST1, ST2, ST3, ST4, ST5, and ST6stacked one on another. The second substrate ST2, the third substrate ST3, the fourth substrate ST4, the fifth substrate ST5, and the sixth substrate ST6may be sequentially stacked on the first substrate ST1. The first substrate ST1may be directly disposed on the stage SG. That is, the first substrate ST1may be a substrate disposed at a lowermost position among the substrates ST, and the sixth substrate ST6may be a substrate disposed at an uppermost position among the substrates ST.

The laser module LR may include a laser beam generator emitting the laser beam and an optical system disposed on a path of the laser bean. The laser beam generator may include a solid laser, such as a ruby laser, a glass laser, an yttrium aluminum garnet (YAG) laser, a yttrium lithium fluoride (YLF) laser, or the like, a gas laser, such as an excimer laser, a helium-neon (He—Ne) laser, or the like, or a pulsed laser.

The optical system may be disposed on a path that follows the laser beam. The optical system may include a homogenizer to homogenize a shape of the laser beam or a condensing lens to focus the laser beam. In addition, the optical system may include at least one mirror disposed on the path of the laser beam to change an angle of the laser beam. The mirror may include a Galvano mirror or a reflective mirror whose angle is changed according to a change in an input voltage.

The controller CT may control a position of the laser module LR or an intensity and a size of the laser beam. The controller CT may move the position of the laser module LR such that the laser beam is irradiated onto the substrates ST along the cutting line CL of the substrates ST. The laser module LR may move in the first direction DR1and the second direction DR2.

According to an embodiment of the present disclosure, the adhesive layer AY may be disposed between the substrates ST. Two substrates adjacent to each other among the substrates ST may be spaced apart from each other in the third direction DR3by the adhesive layer AY. The substrates ST may be stacked with the adhesive layer AY interposed therebetween.

The adhesive layer AY may include first, second, third, fourth, and fifth adhesive layers AY1, AY2, AY3, AY4, and AY5. The first adhesive layer AY1may be disposed between the first substrate ST1and the second substrate ST2. The first substrate ST1and the second substrate ST2may be spaced apart from each other in the third direction DR3with the first adhesive layer AY1interposed therebetween.

Similarly, the second adhesive layer AY2may be disposed between the second substrate ST2and the third substrate ST3. The second substrate ST2and the third substrate ST3may be spaced apart from each other in the third direction DR3with the second adhesive layer AY2interposed therebetween.

The third adhesive layer AY3, the fourth adhesive layer AY4, and the fifth adhesive layer AY5may also have a structure similar to that of the first adhesive layer AY1and the second adhesive layer AY2described above. For instance, the third adhesive layer AY3may be disposed between the third substrate ST3and the fourth substrate ST4, where the fourth substrate ST4is spaced apart from the third substrate ST3in the third direction DR3. The fourth adhesive layer AY4may be disposed between the fourth substrate ST4and the fifth substrate ST5, where the fifth substrate ST5is spaced apart from the fourth substrate ST4in the third direction DR3. The fifth adhesive layer AY5may be disposed between the fifth substrate ST5and the sixth substrate ST6, where the sixth substrate ST6spaced apart from the fifth substrate ST5in the third direction DR3.

In a case were the adhesive layer AY is omitted, the stacked two substrates may be in contact with each other. In this case, a vibration may occur on the substrates stacked on each other when the laser beam is irradiated onto the cutting line. Due to the vibration, a friction may occur between the substrates, and thus, the substrates may be damaged.

According to the present disclosure, the adhesive layer AY may be disposed between each of two substrates adjacent to each other among the stacked substrates ST. For example, when the laser beam is irradiated onto the cutting line CL of the sixth substrate ST6, the vibration may occur in the sixth substrate ST6. Since the sixth substrate ST6and the fifth substrate ST5are spaced apart from each other by the fifth adhesive layer AY5, the friction between the sixth substrate ST6and the fifth substrate ST5caused by the vibration may be prevented. In addition, as the sixth substrate ST6and the fifth substrate ST5are held by the fifth adhesive layer AY5, movement of the sixth substrate ST6and the fifth substrate ST5may be prevented when the cutting operation is performed by irradiating the laser beam.

As described above, when the stacked substrates ST are cut along the cutting line CL, the damage of the substrates may be prevented since the friction between the substrates is prevented by the adhesive layer AY.

In addition, according to an embodiment of the present disclosure, the adhesive layer AY may not overlap the cutting line CL. This is because the intensity of the laser beam may attenuate as the laser beam passes through the adhesive layer. That is, when the laser beam is irradiated onto the cutting line of the substrate after passing through the adhesive layer, the substrate may not be cut.

However, since the adhesive layer AY does not overlap the cutting line CL, the intensity of the laser beam irradiated onto the substrates ST may be maintained.

FIG.2is a plan view showing the first substrate ST1according to an embodiment of the present disclosure.FIG.3Ais a cross-sectional view showing the substrate-cutting apparatus according to an embodiment of the present disclosure.FIG.3Bis a cross-sectional view showing the substrate-cutting apparatus according to an embodiment of the present disclosure.

FIG.2is a plan view of the first substrate ST1. The first substrate ST1may include first, second, third, fourth, fifth, and sixth active areas AA11, AA12, AA13, AA14, AA15, and AA16which are spaced apart from each other when viewed in a plane. The non-active area NAA may surround the first to sixth active areas AA11to AA16.

A first cutting line CL1may correspond to a boundary between the first active, area AA11and the non-active area NAA. A second cutting line CL2may correspond to a boundary between the second active area AA12and the non-active area NAA. A third cutting line CL3may correspond to a boundary between the third active area AA13and the non-active area NAA. A fourth cutting line CL4may correspond to a boundary between the fourth active area AA14and the non-active area NAA. A fifth cutting line CL5may correspond to a boundary between the fifth active area AA15and the non-active area NA. A sixth cutting line CL6may correspond to a boundary between the sixth active area AA and the non-active area NAA.

The second to sixth substrates ST2to ST6may include active areas with substantially the same structure as that of the first substrate ST1.

The first adhesive layer AY1disposed under the first substrate ST1may include first, second, third, fourth, fifth, and sixth adhesive portions AY11, AY12, AY13, AY14, AY15, and AY16respectively overlapping a center portion of the first to sixth active areas AA11to AA16. For example, the first to sixth adhesive portions AY11, AY12, AY13, AY14, AY15, and AY16may not overlap the first to sixth cutting lines CL1to CL6.

For example, as shown inFIG.2, the first active area AA11may surround the first adhesive portion AY11then viewed in a plane. Similarly, the second to sixth active areas AA12to AA16may respectively surround the second to sixth cutting lines CL2to CL6when viewed in a plane.

Referring toFIG.3A, each of the first to fifth adhesive layers AY1to AY5may overlap at least a center portion of the active area AA and may not overlap the non-active area NAA. In particular, each of the first to fifth adhesive layers AY1to AY5may not overlap a cutting area CA corresponding to the cutting line CL shown inFIG.2. As a result, when the laser beam is irradiated onto the cutting area CA, the laser beam may not passing through the adhesive layer AY.

Referring toFIG.3B, when compared with the adhesive layer AY shown inFIG.3A, an adhesive layer AYa may overlap a non-active area NAA. However, the adhesive layer AYa may still not overlap a cutting area CA. As described above, the adhesive layer AYa may be disposed not to overlap the cutting area CA such that the laser beam does not pass through the adhesive layer AYa.

The adhesive layer AYa may include first, second, third, fourth, and fifth adhesive layers AY1a, AY2a, AY3a, AY4a, and AY5a, and each of the first to fifth adhesive layers AY1ato AY5amay be disposed between two corresponding substrates among the first to sixth substrates ST1to ST6. For example, the first adhesive layer AY1amay be disposed between the first substrate ST1and the second substrate ST2, the second adhesive layer AY2amay be disposed between the second substrate ST2and the third substrate ST3, and so on. Each of the first to fifth adhesive layers AY1ato AY5ashown inFIG.3Bmay include a first adhesive portion P1and a second adhesive portion P2, which are spaced apart from each other with the cutting area CA interposed therebetween. The first adhesive portion P1may overlap an active area AA and may correspond to the adhesive portion shown inFIG.2. The second adhesive portion P2may overlap the non-active area NAA. In the following descriptions, the second adhesive portion P2may be referred to as a sub-adhesive portion.

FIGS.4A to4Care perspective views showing a substrate-cutting method according to an embodiment of the present disclosure.

InFIG.4A, the first substrate ST1and the second substrate ST2among the stacked substrates ST shown inFIG.1are shown. The method of cutting the two stacked substrates ST1and ST2is described with reference toFIGS.4A,4B, and4C, however, a method of cutting the plural substrates ST (e.g., more than two substrates) may be substantially the same as the cutting method of the two stacked substrates ST1and ST2.

The laser beam may be irradiated onto each of the first to sixth cutting lines CL1to CL6defined in the second substrate ST2by the laser module LR. The first adhesive layer AY1may not overlap the first to sixth cutting lines CL1to CL6and may be disposed between the first substrate ST1and the second substrate ST2.

Referring toFIG.4B, the substrate-cutting apparatus according to the present disclosure may further include suction pads DMP1, DMP2, DMP3, and DMP4. After the first to sixth cutting lines CL1to CL6are cut using the laser module LR, the suction pads DMP1to DMP4may be suctioned to the second substrate ST2. For example, four suction pads DMP1to DMP4may be disposed at four corners of the second substrate ST2, respectively.

The suction pads DMP1to DMP4may move in the third direction DR3, and accordingly, after a cut process is performed, a portion of the second substrate ST2which corresponds to the non-active area NAA (refer toFIG.2), may be removed.

Referring toFIG.4C, as the portion of the second substrate ST2, which corresponds to the non-active area NAA, is removed, first, second, third, fourth, fifth, and sixth active portions SP1, SP2, SP3, SP4, SP5, and SP6respectively corresponding to the first to sixth active areas AA11to AA16shows inFIG.2may be formed. Each of the first to sixth active portions SP1to SP6may be the window applied to the single display device.

The laser module LR may apply the laser beam onto the cutting line of the first substrate ST1again, and thus, a portion of the first substrate ST1, which overlaps the non-active area, may be removed. As a result, the active portions of the first substrate ST1may be formed.

FIGS.5A to5Care perspective views showing a method of stacking a plurality of substrates according to an embodiment of the present disclosure.

Referring toFIG.5A, a first substrate ST1may be prepared. The first substrate ST1may include a plurality of first active areas AA-1and a first non-active area NAA-1surrounding the first active areas AA-1. A boundary between the first active areas AA-1and the first non-active area NAA-1may be defined as a first cutting line CL-1.

Referring toFIG.5B, a first adhesive layer AY-1may be disposed on the first substrate ST1to overlap at least a center portion of the first active areas AA-1. For example, the first adhesive layer AY-1may include adhesive portions PS respectively overlapping the first active areas AA-1, and each of the adhesive portions PS may be provided in an adhesive resin with a single shape. The adhesive portions PS may not overlap the first cutting line CL1and may be disposed on the first active areas AA-1, respectively,

Referring toFIG.5C, a second substrate ST2may be disposed on the first adhesive layer AY-1. The second substrate ST2may include a plurality of second active areas AA-2and a second non-active area NAA-2surrounding, the second active areas AA-2. A boundary between the second active areas AA-2and the second non-active area NAA-2may be defined as a second cutting line CL-2.

An alignment operation may be performed on the first substrate ST1and the second substrate ST2before the second substrate ST2is disposed on the first adhesive layer AY-1. Accordingly, the first cutting line CL-1of the first substrate ST1and the second cutting line CL-2of the second substrate ST2may be aligned with each other in the third direction DR3.

After the alignment operation is performed on the first substrate ST1and the second substrate ST2, the second substrate ST2may be ire contact with the first adhesive layer AY-1. Then, the cutting operation may be performed on the substrates ST1and ST2using the laser module LR as described with reference toFIGS.4A to4C.

FIGS.6A to6Dillustrate a method of stacking a plurality of substrates according to an embodiment of the present disclosure.

Referring toFIG.6A, a first substrate ST1may have substantially the same configuration as that of the first substrate ST1described with reference toFIG.5A. Accordingly, description of the same components will be made with respect to the present embodiment, and in subsequent descriptions, to the extent any description is omitted, it may be assumed that the components are at least similar to those described here.

A mask MK may be disposed on the first substrate ST1in the process of forming the first adhesive layer AY-1a. The mask MK may be provided with a plurality of opening OP defined therethrough to respectively overlap the first active areas AA-1. The first adhesive layer AY-1a(with reference toFIG.6C) may be formed on the first substrate ST1through the openings OP defined through the mask MK.

In particular, each of the openings OP according to the present embodiment may have a smaller size than that of the first active areas AA-1in a plane. Otherwise, any one adhesive portion among the adhesive portions of the adhesive layer AY-1amay overlap the first cutting line CL-1when the size of the opening OP is greater than that of the first active areas AA-1. Accordingly, the openings OP according to the present disclosure may have a size smaller than that of the first active areas AA-1when viewed in a plane.

Referring toFIG.6B, a resin RS may be coated on the first substrate ST1using the mask MK through which the openings OP are defined. The resin RS may be formed on the first substrate ST1after passing through the openings OP. The resin RS thrilled on the first substrate ST1may be cured. As the openings OP overlap at least a center portion of each of the first active areas AA-1, the resin RS may be formed on the first substrate ST1to overlap at least a center portion of the first active areas AA-1. The resin RS disposed on the mask MK may not be formed on the first substrate ST1.

Referring toFIG.6C, a first adhesive layer AY-1amay be formed through the operation shown inFIG.6B. The first adhesive layer AY-1amay overlap the first active area AA-1and may not overlap the cutting area CA.

Referring toFIG.6D, after an alignment operation is performed on the first substrate ST1and the second substrate ST2, the second substrate ST2may be in contact with the first adhesive layer AY-1a. Then, a cutting operation of the substrates ST1and ST2may be performed using the laser module LR described with reference toFIGS.4A to4C.

Although the embodiments of the present disclosure have been described, it is understood that the present disclosure should not necessarily be limited to these embodiments, and that various changes and modifications can be made by one ordinary skilled in the art within the spirit and scope of the present disclosure as hereinafter claimed. Therefore, the disclosed subject matter should not necessarily be limited to any single embodiment described herein, and the scope of the present inventive concept shall be determined according to the attached claims.