Adhesive Sheet Inclined Side Surface Laser Cutting

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Solution Overview

Problem

Existing adhesive sheets used in display device manufacturing often have uneven cutting surfaces, leading to increased gas penetration and the formation of air bubbles, which result in a poor quality bond and dead space.

Innovation Solution

An adhesive sheet with an inclined side surface, formed by a laser-cutting process, is used to improve the cutting surface quality, reduce air bubble penetration, and minimize dead space during the manufacturing of display devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a blade is used to cut the adhesive, then the adhesive can be cut to the required size, but the cutting surface becomes uneven

Engineering Contradiction:

Improvecutting speedVSAvoidcutting surface quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces the mechanical blade cutting system with a laser cutting system. The laser beam eliminates the need for physical contact with the adhesive material, thereby preventing mechanical damage and surface unevenness while maintaining high cutting speed. The laser selectively removes material through thermal ablation, producing a clean, uniform cutting surface.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the cutting mechanism from mechanical force to thermal energy by using laser radiation. By controlling laser parameters such as power, pulse duration, and scanning speed, the system achieves precise control over the cutting process, ensuring a uniform cutting surface quality while maintaining productivity.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If the cutting surface is uneven, then the adhesive can be easily cut, but external gas penetration increases

Engineering Contradiction:

Improvecutting easeVSAvoidgas penetration

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The laser cutting system replaces mechanical cutting that creates uneven surfaces with a non-contact thermal process. This substitution eliminates surface irregularities that would otherwise create pathways for gas penetration, while the laser's precision ensures clean cuts that maintain sealing integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the potential harm of laser heat affecting the adhesive into a benefit by using controlled thermal ablation. The laser energy is precisely controlled to remove only the necessary amount of material, creating a clean cutting surface that prevents gas penetration rather than damaging the adhesive structure.

Inventive Principle:

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

3Device complexity

If the adhesive is cut with a blade, then the cutting process is simple, but air bubbles penetrate more easily

Engineering Contradiction:

Improvecutting process complexityVSAvoidbond quality

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces the simple but defective mechanical blade cutting with a laser cutting process. Although the laser system is more complex than a blade, it eliminates the surface unevenness and contamination that cause air bubble penetration, thereby improving bond quality and reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser cutting process creates a clean, precise copy of the desired cut geometry without introducing mechanical damage. The thermal ablation process replicates the cutting function of a blade while producing a superior surface quality that prevents air bubble formation and penetration.

Inventive Principle:

Principle #26Copying

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 improved adhesive sheet effectively prevents air bubble penetration and reduces dead space, resulting in a higher quality bond and more efficient display device manufacturing process.

Implementation Method 1

a side surface extending from an edge of the lower surface to an edge of the upper surface, wherein the side surface is cut by a laser beam

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS20250188317A1Adhesive sheet and method for manufacturing display device using the same

Publication Date: 2025.06.12 SAMSUNG DISPLAY CO LTD

AI summary

An adhesive sheet including a first release film, a second release film disposed on the first release film, and an adhesive layer disposed between the first release film and the second release film, the adhesive layer including an upper surface facing the second release film, a lower surface facing the first release film, and a side surface extending from an edge of the lower surface to an edge of the upper surface. The side surface of the adhesive layer may be inclined with respect to a direction perpendicular to the upper surface and the lower surface.