Display Panel Hole Cutting with Multi-Power Laser Sequencing
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Solution Overview
Problem
Existing display devices face challenges in accurately defining holes for functional elements and suffer from potential damage during manufacturing processes.
Innovation Solution
A method involving the use of intense light, such as laser cutting, is employed to precisely define holes in the display panel by irradiating first and second intense lights with varying power levels to cut through multiple layers, ensuring accurate hole formation and minimizing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cutting methods are used to define holes in the display panel, then the manufacturing process is simpler, but the hole definition accuracy is insufficient and damage to the display device occurs
Solution Approach 1:
The patent divides the cutting process into multiple stages using different laser beams with different power levels. A first laser beam performs initial cutting at lower power to define the hole boundaries, while a second laser beam with higher power completes the cutting through remaining layers. This segmentation allows precise hole definition without requiring a single complex high-power cutting operation that would cause damage.
Solution Approach 2:
The patent changes the power parameter of the laser beam between different cutting stages. The first laser beam operates at a lower power level suitable for precise initial cutting, while the second laser beam operates at a higher power level to complete the cutting through additional layers. This parameter change enables both high precision and complete material removal without damage.
2Ease of manufacture
If a single high-power laser beam is used to cut through all layers, then the manufacturing process is simpler, but damage to the display device occurs
Solution Approach 1:
The patent segments the cutting operation into two sequential steps with different laser beams. The first laser beam performs initial cutting at lower power, and the second laser beam completes the cutting at higher power. This segmentation prevents damage by avoiding the use of high power throughout the entire process, while still achieving complete material removal.
Solution Approach 2:
The first laser beam performs a preliminary cutting action that defines the hole boundaries and removes material from the surface layers. This preliminary action prepares the structure for the second laser beam to complete the cutting through remaining layers with higher power, minimizing damage by performing the delicate initial work first.
3Manufacturing precision
If multiple laser beams with different power levels are used to cut through multiple layers, then hole definition accuracy is improved and damage is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent maintains continuous useful action by using two laser beams in sequence without interruption to the cutting process. The first laser beam defines the hole boundaries and the second laser beam completes the cutting through remaining layers, ensuring continuous material removal without idle time. This continuous action achieves high precision while minimizing total processing time.
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 precise hole definition and reduces damage to the display device during manufacturing, enhancing the accuracy and integrity of the final product.
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
Implementation Method 2
irradiating a first intense light from a side of the first protective film toward the cutoff line to cut portions
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.