Semi-automated reworkability process for de-bonding a display

• US 8,419,896 B2
• Filed: 11/20/2009
• Issued: 04/16/2013
• Est. Priority Date: 11/20/2008
• Status: Active Grant

• Current Assignee: DuPont Electronics, Inc. (DuPont de Nemours, Inc.)
• Original Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Inventors: Ciliberti, Michael N., Dodson, Charles W. Jr.
• Primary Examiner(s): Osele, Mark A
• Assistant Examiner(s): HARM, NICKOLAS R
• Application Number:
  US13/120,458
• Publication Number:
  US 20110180218A1
• Time in Patent Office: 1,243 Days
• Field of Search: 156/703, 156/705, 156/711, 156/717, 156/761, 156/762
• US Class Current: 156/717
• CPC Class Codes: G02F 1/1303 Apparatus specially adapted to the manufacture of LCDs
• CPC Class Codes: G02F 1/1309 Repairing; Testing
• CPC Class Codes: Y10T 156/11 Methods of delaminating, per se; i.e. , separating at bonding face
• CPC Class Codes: Y10T 156/1111 Using solvent during delaminating [e.g., water dissolving adhesive at bonding face during delamination, etc.]
• CPC Class Codes: Y10T 156/1121 Using vibration during delaminating
• CPC Class Codes: Y10T 156/1153 Temperature change for delamination [e.g., heating during delaminating, etc.]
• CPC Class Codes: Y10T 156/1184 Piercing layer during delaminating [e.g., cutting, etc.]
• CPC Class Codes: Y10T 156/1961 Severing delaminating means [e.g., chisel, etc.]
• CPC Class Codes: Y10T 156/1967 Cutting delaminating means

Abstract

A method for reworking a bonded display (e.g., a bonded LCD) having a substrate (e.g., plate or film) adhesively bonded to a face (e.g., front face) of the display. The method provides for efficient and clean removal of the substrate from the bonded display when necessary (e.g., when defect(s) are present) to afford a de-bonded display that is undamaged such that the resulting de-bonded display (e.g., de-bonded LCD) can subsequently be re-bonded as a component in a device being manufactured.

Claims

1. A method for reworking a bonded display having a surface and a substrate adhesively bonded with a cured adhesive layer to the surface of the display, the method comprising:

a) advancing the bonded display, from an edge or a corner of the display to an opposing edge or an opposing corner of the display, through a moving line in a manner such that the cured adhesive layer contacts the moving line resulting in break-up of the adhesive layer such that the substrate is no longer bonded to the display; and

b) removing the cured adhesive layer from the display to afford a de-bonded display and the substrate;

wherein the moving line is fed from a first spool and collected using a second spool following its being fed from the first spool and used in de-bonding to afford the de-bonded display and the substrate and the moving line is comprised of a braided material.

2. The method of claim 1 wherein the moving line is within 10 degrees of being orthogonal to the direction that the cured adhesive layer is being advanced.

3. The method of claim 1 wherein the moving line is selected from the group consisting of a fiber, a rope, a thread, and a wire.

4. The method of claim 1 wherein the moving line comprises a polymeric non-woven material.

5. The method of claim 1 wherein the moving line comprises a spun material.

6. The method of claim 1 wherein the moving line has a line speed that ranges from 1 foot/minute to 80 feet/minute.

7. The method of claim 6 wherein the table speed ranges from about 0.5 feet/minute to about 2.0 feet/minute.

8. The method of claim 1 wherein the bonded display is advanced through the line to effect de-bonding of the display at a rate ranging from about 0.01 feet/minute to about 10 feet/minute.

9. The method of claim 1 wherein the bonded display is contained within a holder during execution of the method to effect de-bonding.

10. The method of claim 1 wherein the moving line comprises a metal.

11. The method of claim 1 wherein the moving line comprises a textured conductive material having a rough surface.

12. The method of claim 1 wherein the moving line is a heated element that is heated to a temperature above ambient temperature during execution of the method.

13. The method of claim 1 wherein the moving line comprises a chemically pretreated element, the element having been treated prior to use with a chemical that serves to afford bond breakage of the cured adhesive layer.

14. The method of claim 1 wherein the moving line has a tensile strength (measured in pounds) to diameter (measured in millimeters) ratio of at least 80 pounds per millimeter for reworking a bonded display having a smaller side dimension of greater than 4 inches.

15. The method of claim 1 wherein the moving line has a tensile strength (measured in pounds) to diameter (measured in millimeters) ratio of at least 40 pounds per millimeter for reworking a bonded display having a smaller side dimension of less than or equal to 4 inches.

16. The method of claim 1 wherein the surface of the display is a front surface.

17. The method of claim 1 wherein the cured adhesive layer is one obtained by curing of a liquid photocurable adhesive.

18. The method of claim 1 wherein the moving line is operated at a line speed ranging from about 30 feet/minute to about 40 feet/minute.

19. The method of claim 1 wherein the table speed ranges from about 0.5 feet/minute to about 2.0 feet/minute.

20. A method for reworking a bonded liquid crystal display having a surface and a substrate adhesively bonded with a cured adhesive layer to the surface of the display, the method comprising:

a) advancing the bonded liquid crystal display, from an edge or a corner of the display to an opposing edge or an opposing corner of the display, through a moving line in a manner such that the cured adhesive layer contacts the line resulting in break-up of the adhesive layer such that the substrate is no longer bonded to the liquid crystal display; and

b) removing the cured adhesive layer from the liquid crystal display to afford a de-bonded liquid crystal display and the substrate.

wherein the moving line is fed from a first spool and collected using a second spool following its being fed from the first spool and used in de-bonding to afford the de-bonded display and the substrate and the moving line is comprised of a braided material.