Display Panel Edge Block Strip for Laser-Cut Light Leakage
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Solution Overview
Problem
Current micro-LED display manufacturing methods using mass transfer technology face issues with edge light leakage due to thermal impact from laser cutting, causing encapsulant retraction and thin adhesive layers, which affect display quality and yield.
Innovation Solution
Incorporating a block strip between the encapsulation layer and substrate, which absorbs less than 0.1% of infrared laser heat, preventing excessive heat transfer and maintaining encapsulant thickness, thereby preventing edge light leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser cutting is used to cut the glass substrate and encapsulant simultaneously, then the manufacturing process is simplified, but the thermal impact range on the encapsulant becomes too large causing encapsulant retraction and edge light leakage
Solution Approach 1:
The patent introduces a block strip as a separate component positioned between the encapsulant and glass substrate at the edge region. This segmentation allows the laser cutting process to be spatially divided: the block strip absorbs excess thermal energy while the encapsulant remains protected, enabling simultaneous cutting without encapsulant damage.
Solution Approach 2:
The block strip serves as a thermal intermediary or buffer between the laser cutting zone and the encapsulant. It absorbs the excessive thermal impact from laser cutting, preventing heat transfer to the encapsulant that would cause retraction and edge thinning, thus enabling the simplified simultaneous cutting process.
2Productivity
If high power laser is used for cutting, then cutting efficiency is improved, but the thermal impact causes encapsulant retraction and edge light leakage
Solution Approach 1:
The patent converts the harmful thermal impact of high-power laser cutting into a beneficial effect by introducing the block strip. The block strip is specifically designed to absorb the excess thermal energy that would otherwise damage the encapsulant, allowing high-power laser cutting to proceed efficiently without causing encapsulant retraction or edge light leakage.
Solution Approach 2:
The block strip acts as a thermal mediator between the high-power laser and the encapsulant. It intercepts and absorbs the excessive thermal energy, protecting the encapsulant from harmful thermal effects while allowing the high-power laser to maintain its cutting efficiency.
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 block strip effectively reduces heat absorption by the encapsulation layer during cutting, maintaining edge thickness and preventing light leakage, thus enhancing display quality and production yield by eliminating tiling line defects in spliced displays.
Implementation Method 1
an absorption rate of the block strip to infrared laser is less than 0.1%
Implementation Method 2
laser cutting is currently used to cut the glass substrate and encapsulant simultaneously
Data Source
AI summary
A display panel including a substrate, multiple display units, an encapsulation layer, and a block strip is disclosed. The display units are disposed over the substrate. The encapsulation layer is disposed over the substrate and between the display units. The block strip is disposed between the encapsulation layer and the substrate, and extends along an edge of the substrate.