Curved Display Panel Substrate Stress Management
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Solution Overview
Problem
Current curved display panels face challenges in maintaining optimal curvature and strength, leading to potential cracking issues due to uneven tensile stress and surface roughness, which affects their three-dimensional effect and durability.
Innovation Solution
A display panel design featuring substrates with specifically curved side surfaces and varying roughness, where one substrate is positioned closer to the reference axis than the other, with a sealant structure that includes sub-sealants with constant hardness, and a manufacturing method involving wheel cutting and laser cutting processes to define and separate display unit cells, ensuring reduced cracking and improved curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the display panel is curved to provide three-dimensional effect, then the immersive experience is improved, but the risk of cracking increases due to uneven tensile stress
Solution Approach 1:
The patent applies different roughness levels to different side surfaces of the substrates. Specifically, the first side surfaces (facing the reference axis) have different roughness compared to the second side surfaces. This local differentiation in surface quality allows for optimized stress distribution across the curved structure, reducing cracking risks while maintaining the desired curved shape for three-dimensional display effect.
2Strength
If the substrates are curved with varying roughness, then the tensile stress distribution is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent incorporates dummy areas with specific roughness characteristics into the substrate structure before final assembly. These dummy areas are pre-formed with controlled roughness during substrate preparation, allowing the actual display area to achieve optimal tensile stress distribution without requiring complex post-processing. The dummy areas serve as stress management zones that are manufactured in advance as part of the substrate fabrication process.
3Shape
If the first side surfaces have different roughness, then the curved characteristics are enhanced, but the surface quality control becomes more difficult
Solution Approach 1:
The patent deliberately creates local quality differences by assigning different roughness levels to different side surfaces. The first side surfaces (facing the reference axis) have one roughness level while the second side surfaces have another level. This controlled local differentiation enhances the curved characteristics and three-dimensional appearance while the manufacturing process manages surface quality control through targeted treatment of specific zones rather than requiring uniform precision across all surfaces.
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 solution enhances the curved characteristics of display panels by reducing cracking risks and maintaining strength, providing improved three-dimensional effects and durability through precise substrate positioning and cutting techniques.
Implementation Method 1
separating the dummy area from the divided display unit cell by performing a laser cutting process
Data Source
AI summary
A method of manufacturing a display panel includes providing a mother substrate in which a plurality of display cell areas is defined from which the display panel will be formed, the display cell areas arranged in along first and directions and each include a display unit cell corresponding to the display panel, and a dummy area extended along the second direction from the display unit cell dividing the mother substrate into the display unit cells each having the dummy area extended therefrom, by performing a wheel cutting process; separating the dummy area from the divided display unit cell by performing a laser cutting process; and curving the display unit cell from which the dummy area is separated, with reference to a reference axis which is parallel to the second direction, to form the display panel.