Axicon Bessel Beam Scanning for Precise Narrow-Bezel Display Cutting
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Solution Overview
Problem
The challenge in manufacturing display devices is the limited reduction of the non-display area, particularly the second non-display area, which hinders the enhancement of the display device's aesthetic appearance and immersion due to constraints on the number of lines and circuits, and existing laser processing methods do not adequately address the precision and efficiency required for cutting mother substrates.
Innovation Solution
An apparatus comprising a light source, a beam converter with an axicon lens and relay lens, and a scanner with mirrors, which converts a Gaussian beam into a ring-shaped Bessel beam for precise processing, allowing for improved optical properties such as numerical aperture, beam size, and optical aberration, enabling efficient cutting and patterning of display panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the width of the second non-display area is reduced to enhance aesthetic appearance and immersion, then the display area becomes more immersive and aesthetically pleasing, but the manufacturing precision and cutting accuracy become more difficult to maintain
Solution Approach 1:
The patent changes the beam parameters by converting from a Gaussian beam to a Bessel beam, which maintains a long depth of field and small beam waist. This parameter change allows for precise cutting with reduced beam divergence, enabling accurate processing even when the non-display area is minimized.
Solution Approach 2:
The patent replaces conventional mechanical cutting methods with laser beam processing. The laser processing apparatus uses optical fields instead of mechanical contact to achieve precise cutting, eliminating mechanical tolerances and enabling higher precision in the cutting process.
2Ease of manufacture
If conventional laser processing is used for cutting mother substrates, then the process is simple and easy to implement, but the precision and efficiency are insufficient for modern display device manufacturing requirements
Solution Approach 1:
The patent transforms the laser beam from a conventional Gaussian profile to a Bessel beam profile using an axicon lens. This parameter change in beam shape provides a long depth of field and consistent beam waist, significantly improving cutting precision while maintaining ease of manufacture through the standardized optical components.
Solution Approach 2:
The patent introduces a scanning mechanism that periodically moves the laser beam across the mother substrate in a controlled manner. This periodic scanning action enables precise and efficient cutting by systematically covering the entire cutting path with consistent beam parameters.
3Productivity
If the beam size and numerical aperture are increased to improve processing efficiency, then the cutting speed increases, but the optical aberration and beam quality deteriorate
Solution Approach 1:
The patent changes the beam profile from Gaussian to Bessel, which fundamentally alters the beam's propagation characteristics. The Bessel beam maintains a constant beam waist over a long distance and is less sensitive to aperture limitations, allowing for high numerical aperture and large beam size without significant quality degradation, thus improving cutting speed while maintaining beam quality.
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 apparatus enhances the precision and efficiency of cutting and patterning, reducing the non-display area while maintaining high energy concentration and uniform processing, thereby improving the display device's aesthetic appeal and performance.
Implementation Method 1
a beam converter including an axicon lens for converting the first beam into a second beam and a relay lens for converting the second beam into a third beam
Implementation Method 2
a scanner including a first mirror for reflecting the third beam in a first direction and a second mirror for reflecting the third beam in a second direction different from the first direction
Implementation Method 3
a scan lens having an effective focal length and being for converting the third beam output from the scanner into a fourth beam
Implementation Method 4
A laser beam used in laser processing has strong directivity and high density. In particular, a high-power laser beam that does not affect the surrounding material and enables precision processing can be used to process a display panel
Data Source
AI summary
An apparatus for manufacturing a display device includes: a light source for generating a first beam; a beam converter including an axicon lens for converting the first beam into a second beam and a relay lens for converting the second beam into a third beam; a scanner including a first mirror for reflecting the third beam in a first direction and a second mirror for reflecting the third beam in a second direction different from the first direction; and a scan lens having an effective focal length and being for converting the third beam output from the scanner into a fourth beam. The scan lens including first through fifth lens respectively having first through fifth focal lengths and a cover window. An absolute value of the first focal length is smaller than an absolute value of each of the second through fifth focal lengths.