Curved Display Edge Laser Shaping for Impact Resistance

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Solution Overview

Problem

Curved display panels are more susceptible to impact damage due to their shape, as the curved portions absorb impact in a dot contact form, making them vulnerable compared to linear portions which absorb impact in a surface contact form.

Innovation Solution

A display device design that includes a linear portion and a curved portion, where the outer surface of the curved portion is modified to be more resistant to impact by varying the width and angle of the substrate surfaces, and a laser processing method that applies different conditions for forming the linear and curved portions to enhance the edge shape, using a laser processing apparatus with a controller to control the laser application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a curved display panel is used to achieve a curved shape, then the display device has aesthetic appeal and flexibility, but the curved portion becomes more susceptible to impact damage

Engineering Contradiction:

Improvecurved shapeVSAvoidimpact resistance

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent applies local quality by creating a deformed portion with different geometric properties at the curved portion of the display panel. Specifically, the outer surface of the curved portion is modified to have a larger radius of curvature or a flattened region, making this local area more resistant to impact while preserving the overall curved shape aesthetic. This localized structural modification allows the curved portion to better distribute impact forces without compromising the global curved design.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent implements beforehand cushioning by pre-forming a deformed portion at the curved area that acts as a buffer zone. This deformed portion, created through laser processing or other manufacturing methods, provides a cushioning effect before impact occurs, absorbing and distributing impact energy to prevent damage to the main display panel structure.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If the outer surface of the curved portion is modified to improve impact resistance, then reliability is enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improveimpact resistanceVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical methods of creating curved portions with laser processing technology. Instead of using complex mechanical forming equipment to create the deformed portion, a laser is used to selectively heat and deform the substrate material. This substitution simplifies the manufacturing process by eliminating the need for specialized mechanical forming tools while achieving the same structural modification.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies parameter changes by modifying the geometric parameters of the curved portion through controlled laser processing. The laser processing parameters (power, speed, focal point) are adjusted to create the desired deformed portion with specific geometric characteristics that enhance impact resistance. This allows precise control over the shape and dimensions of the deformed portion without requiring complex tooling.

Inventive Principle:

Principle #35Parameter changes

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 modified display device exhibits improved resistance to external impacts, enhancing the reliability and durability of the curved portions, allowing them to withstand external forces better.

Implementation Method 1

forming a linear portion of the object to be processed by performing a first laser processing for the object to be processed; and forming a curved portion of the object to be processed by performing a second laser processing different from the first laser processing

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

The controller controls the irradiation unit to form a linear portion of the object to be processed by applying the laser onto the object to be processed according to a first condition and form a curved portion of the object to be processed by applying the laser onto the object to be processed according to a second condition different from the first condition

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS11971751B2Display device, method for manufacturing the device and laser processing apparatus for manufacturing the display device

Publication Date: 2024.04.30 SAMSUNG DISPLAY CO LTD

AI summary

A method of manufacturing a display device, including: providing an object to be processed; forming a linear portion of the object to be processed by performing a first laser processing for the object to be processed; and forming a curved portion of the object to be processed by performing a second laser processing different from the first laser processing for the object to be processed. A laser processing apparatus, is also provided, including: an irradiation unit applying a laser onto an object to be processed; and a controller controlling an operation of the irradiation unit. The controller controls the irradiation unit to form a linear portion of the object to be processed by applying the laser onto the object according to a first condition and forming a curved portion of the object by applying the laser onto the object according to a second condition different from the first condition.