Display Panel Edge Laser Processing for Zero-Bezel Polarizer Alignment

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Solution Overview

Problem

Conventional display device manufacturing methods result in a step difference between the display panel and the polarizing layer, leading to bezel formation and light leakage, which limits the reduction of bezel width and hinders the achievement of ultra-high resolution displays.

Innovation Solution

The method involves disposing a polarizing layer on a display panel, cutting it using a laser beam to remove the step difference, applying and patterning a conductive paste using a patterning laser to form ultra-fine conductive patterns, and electrically connecting a driving circuit through side bonding, thereby eliminating the bezel and enabling ultra-high resolution displays.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional manufacturing methods are used with polishing and screen printing, then the display panel can be manufactured, but a step difference between the display panel and polarizing layer is formed, creating bezel and light leakage

Engineering Contradiction:

Improveflatness of side surfaceVSAvoidbezel and light leakage

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent replaces mechanical polishing with laser processing to achieve a flat side surface. The laser processing method eliminates the need for mechanical contact and polishing compounds, directly removing material to create a flat surface that prevents step differences between the display panel and polarizing layer, thereby eliminating bezel and light leakage issues.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the manufacturing parameters by using laser processing instead of mechanical polishing. This parameter change enables precise control of the side surface flatness and eliminates the step difference problem that occurs with conventional mechanical methods, resolving the bezel and light leakage issues.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If conventional screen printing is used for conductive paste patterning, then conductive patterns can be formed, but ultra-fine patterns cannot be achieved

Engineering Contradiction:

Improvepattern widthVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces screen printing with laser scribing for conductive paste patterning. The laser scribing method uses a focused laser beam to precisely remove conductive paste material, enabling the formation of ultra-fine patterns with widths of several micrometers or less, which cannot be achieved with conventional screen printing methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser scribing process uses periodic pulsed laser action to remove conductive paste material. The pulsed laser delivers energy in short bursts, allowing precise material removal through ablation while controlling heat accumulation, enabling ultra-fine pattern formation with clean edges and high precision.

Inventive Principle:

Principle #19Periodic action

3Device complexity

If polarizing layer is applied early in the manufacturing process, then the process can be simplified, but the step difference problem persists

Engineering Contradiction:

Improvemanufacturing process stepsVSAvoidside surface flatness

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent applies the polarizing layer early in the manufacturing process, before the side surface is fully processed. This preliminary action allows the polarizing layer to be applied to a larger area including the side edges, and subsequent laser processing of the side surface creates a flat transition that eliminates step differences, simplifying the overall process while maintaining precision.

Inventive Principle:

Principle #10Preliminary action

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 manufacturing time and cost, allows for the formation of zero-bezel displays with ultra-high definition, and enhances the edge strength of the display panel, enabling large-sized displays with higher resolutions.

Implementation Method 1

cutting it using a laser beam to remove the step difference, applying and patterning a conductive paste using a patterning laser

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

cutting it using a laser beam to remove the step difference, applying and patterning a conductive paste using a patterning laser to form ultra-fine conductive patterns

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentEP3614197B1Method of manufacturing a display device

Publication Date: 2021.11.10 SAMSUNG DISPLAY CO LTD

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AI summary

A method of manufacturing a display device includes disposing a polarizing layer on one surface of a display panel including a thin film transistor and a pixel electrode; cutting the polarizing layer using a cutting laser beam such that a side of the polarizing layer and a side of the display panel correspond to each other; applying a conductive paste on the side of the display panel; and patterning the conductive paste using a patterning laser beam.