Display Panel Hole Formation Across Films and Adhesives
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Solution Overview
Problem
Existing display device manufacturing methods face challenges in accurately defining holes for functional elements and often result in damage to the display device during the cutting process.
Innovation Solution
A method involving a display panel with a light blocking area, a polarizing film, and adhesives, where intense laser lights of different powers are used to cut through specific layers to define precise holes for functional elements like cameras, while minimizing damage by controlling the cutting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single intense laser light is used to cut through all layers, then the cutting speed is improved, but the display device suffers damage due to excessive heat and energy
Solution Approach 1:
The patent divides the laser cutting process into multiple sequential steps using different laser lights. First, a first intense laser light cuts through rigid layers (display panel, polarizing film, protective films). Then, a second intense laser light with different parameters cuts through adhesive layers. This segmentation allows each laser to be optimized for its specific target material, achieving high cutting speed while minimizing damage to the display device.
Solution Approach 2:
The patent applies different laser cutting parameters to different layers based on their specific properties. The first laser light uses parameters suitable for cutting rigid materials, while the second laser light uses parameters optimized for adhesive materials. This local quality approach ensures that each layer receives the appropriate cutting energy, improving overall cutting efficiency while preventing damage to sensitive components.
2Manufacturing precision
If multiple laser lights with different powers are used to cut different layers, then the manufacturing precision is improved, but the process complexity increases
Solution Approach 1:
The patent segments the cutting process into distinct sequential steps, each handled by a specialized laser light. The first laser light handles rigid layers with specific parameters, while the second laser light handles adhesive layers with different parameters. This segmentation enables precise control over each cutting operation, achieving high manufacturing precision while keeping the process manageable through systematic organization.
Solution Approach 2:
The patent performs preliminary actions by pre-positioning protective films and adhesive layers in specific configurations before the cutting process. The protective films are placed to protect sensitive areas, and the adhesive layers are positioned to be cut last. This preliminary arrangement simplifies the subsequent cutting process by establishing a clear cutting sequence, reducing the complexity of coordinating multiple laser lights.
3Loss of time
If protective films and adhesive layers are cut simultaneously, then the manufacturing time is reduced, but the hole accuracy deteriorates due to interference between layers
Solution Approach 1:
The patent segments the cutting process into sequential steps rather than simultaneous operations. The first laser light completes cutting of rigid layers, then the second laser light completes cutting of adhesive layers. This segmentation eliminates interference between different cutting operations, ensuring high hole accuracy while maintaining efficient manufacturing time through systematic processing.
Solution Approach 2:
The patent uses preliminary action by positioning protective films and adhesive layers in a predetermined sequence that facilitates sequential cutting. The protective films are placed to be cut first, followed by adhesive layers. This preliminary arrangement ensures that each layer is cut when it is most accessible and stable, achieving both high accuracy and efficient timing without interference between operations.
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 allows for more accurate and precise definition of holes, reducing damage to the display device and improving the manufacturing process efficiency.
Implementation Method 1
irradiating a first intense light from a side of the first protective film toward the cutoff line to cut portions of the first protective film, the display panel, and the polarizing film, which overlap the cutoff area
Implementation Method 2
irradiating a second intense light from a side of the first protective film toward the cutoff line to cut portions of the first adhesive, the deco film, and the second protective film, which overlap the cutoff area
Data Source
AI summary
A display device includes a display panel including a display area including a light blocking area and a non-display area around the display area, a base film disposed on the display panel, a light blocking layer that overlaps the light blocking area and is disposed on a surface of the base film, a first adhesive disposed between the display panel and the base film, a window disposed on the base film, and a second adhesive disposed between the window and the base film. A first hole defined in a portion of the light blocking area passes through the base film, the light blocking layer, the first adhesive, and the second adhesive.