Curved Display Panel Protrusion Thickness Control via Selective Etching
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Solution Overview
Problem
The existing methods for manufacturing curved display panels face high defect rates due to etchant infiltration and require reinstallation of seals, making it difficult to achieve a slim, durable design.
Innovation Solution
A method involving mechanical polishing of protrusions to reduce thickness, followed by installation of a sealing member to protect the panel from etchant, and etching both surfaces excluding the sealed areas, minimizes etchant exposure and eliminates the need for seal reinstallation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If double etching is performed to reduce protrusion thickness, then the protrusion height is reduced, but the defect rate increases due to etchant infiltration
Solution Approach 1:
The patent applies preliminary action by performing mechanical polishing on the protrusion before etching to pre-reduce its thickness. This preliminary reduction minimizes the amount of etching needed, thereby reducing etchant exposure time and infiltration risk while still achieving the desired thin profile for curved display manufacturing
2Manufacturing precision
If double etching is performed to reduce protrusion thickness, then the protrusion height is reduced, but the manufacturing process complexity increases
Solution Approach 1:
The patent merges multiple operations into a unified process sequence: mechanical polishing is combined with selective masking and etching in a coordinated workflow. The masking step is strategically positioned to protect specific areas during etching, allowing the protrusion to be precisely shaped in a single etching operation rather than requiring multiple separate etching steps
3Length of moving object
If the entire display panel is etched to reduce thickness, then the panel becomes thinner and more bendable, but the seal thickness becomes mismatched requiring reinstallation
Solution Approach 1:
The patent applies local quality by using selective masking to protect different regions of the display panel during etching. The mask is applied to specific areas where seals are located, allowing those regions to maintain their original thickness while the rest of the panel is thinned. This creates localized thickness variation that matches the seal dimensions, eliminating the need for seal reinstallation
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
This approach reduces defect rates by minimizing etchant infiltration and eliminates the inconvenience of seal reinstallation, enabling the production of thinner, more durable curved display panels.
Implementation Method 1
both surfaces of a display panel are etched using an etchant so that the display panel has a small thickness
Implementation Method 2
installing a sealing member, which protects the flat display panel, polished in the polishing, from an etchant by surrounding both the portion that is to form the protrusion and the drive circuit board
Implementation Method 3
polishing a portion of the flat display panel that is to form a protrusion, which protrudes in order to protect a portion, to which a drive circuit board is attached, through mechanical polishing
Data Source
AI summary
A method of manufacturing a curved display panel, includes: polishing a portion of the flat display panel that is to form a protrusion, which protrudes in order to protect a portion, to which a drive circuit board is attached, through mechanical polishing so as to have a preset thickness; installing a sealing member, which protects the flat display panel, polished in the polishing, from an etchant by surrounding both the portion that is to form the protrusion and the drive circuit board; and etching an entirety of both surfaces of the flat display panel using the etchant, excluding a portion on which the sealing member is provided, so that the flat display panel, having the sealing member installed in the installing, has a thickness smaller than a thickness of the protrusion.