Curved Cut Surfaces in Flat Panel Displays
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional flat panel display manufacturing methods result in rectangular shapes with right-angle corners, which reduce the strength of the display device and require an edge grinding process that can introduce defects, such as glass powder into liquid crystal displays.
Innovation Solution
The use of a short-pulse laser beam to create curved cut surfaces on both substrates, eliminating the need for edge grinding and enhancing the mechanical strength by dispersing stress effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional cutting methods are used to create rectangular shapes with right-angle corners, then manufacturing simplicity is maintained, but mechanical strength is reduced and edge grinding is required
Solution Approach 1:
The patent applies curvature to the cut surfaces by forming rounded corners with a specific radius of curvature (R1) instead of sharp right angles. This curvature disperses stress concentration at the corners, significantly improving mechanical strength while maintaining manufacturing efficiency through a single laser processing step that combines cutting and rounding operations.
Solution Approach 2:
The patent replaces the conventional mechanical cutting process (which requires subsequent edge grinding) with laser processing. The laser directly creates the curved cut surface in one operation, eliminating the need for mechanical edge grinding equipment and multiple processing steps, thereby maintaining ease of manufacture while improving strength.
2Manufacturing precision
If edge grinding process is performed after cell cutting, then cut surface quality is improved, but productivity is reduced and defects such as glass powder are introduced
Solution Approach 1:
The patent merges the cutting operation and the edge rounding operation into a single laser processing step. The laser beam simultaneously performs both functions, creating the curved cut surface without requiring a separate edge grinding process, thus maintaining high productivity while achieving excellent cut surface quality free from glass powder defects.
Solution Approach 2:
The patent substitutes mechanical edge grinding with laser processing. The laser directly forms the curved cut surface with high precision, eliminating the mechanical grinding process that reduces productivity and introduces harmful glass powder particles into the display device.
3Reliability
If right-angle corners are used in cut surfaces, then manufacturing complexity is minimized, but stress concentration occurs reducing device reliability
Solution Approach 1:
The patent introduces curved corners with a controlled radius of curvature (R1) to eliminate stress concentration at the corners. This geometric modification significantly improves device reliability by dispersing stress, while the curvature parameter is optimized to maintain reasonable manufacturing complexity without requiring overly complex processing equipment or procedures.
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 method produces display devices with increased mechanical strength and a sleeker appearance, reducing the risk of damage from external impacts and eliminating the need for post-processing grinding, thereby improving productivity and preventing defects.
Implementation Method 1
irradiating a short-pulse laser beam swung by a light swing unit to a light irradiation region defined on the mother substrates, transferring either or both of the light swing unit and the stage to move the light irradiation region along an imaginary cut line where the mother substrates are to be cut, and cutting the mother substrates
Data Source
AI summary
A method of manufacturing a flat panel display is disclosed. In one aspect, the method includes preparing first and second mother substrates, forming a plurality of display cells on at least one of the mother substrates, forming a plurality of sealant lines enclosing the respective cells on either one of the mother substrates and assembling and sealing the two mother substrates with the sealant lines interposed therebetween. The method also includes mounting the two mother substrates on a stage, irradiating a laser beam to a defined light irradiation region of the mother substrates and cutting the mother substrates while moving the light irradiation region along an imaginary cut line where the mother substrates are to be cut. The light irradiation region includes a linear region and a curved region.