Display Module Lamination and Co-Cutting for Narrow Bezel Edges
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Solution Overview
Problem
As display devices become smaller, the bezel area to front surface ratio becomes a critical design factor, and existing manufacturing methods do not effectively reduce this ratio.
Innovation Solution
A method involving defining an etching line on a metal plate with higher rigidity than the display panel, etching the metal plate along this line, laminating it to the display module, and cutting both together along a corresponding cutting line to align edge parts and reduce laminating tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the display device is made smaller, then the portability and compactness are improved, but the bezel area to front surface ratio increases
Solution Approach 1:
The patent merges the metal plate and display module into a single laminated structure that is cut together as one unit. This integration ensures that the metal plate precisely covers the display module with minimal gaps, reducing the bezel area while maintaining structural integrity and alignment in the compact display device.
Solution Approach 2:
The patent applies preliminary etching to the metal plate along a closed curve before lamination, creating precise recesses that anticipate the final shape requirements. This preliminary shaping allows the metal plate to conform exactly to the display module contours after cutting, minimizing bezel area in the compact device.
2Adaptability or versatility
If the metal plate and display module are cut separately, then the cutting flexibility is improved, but the alignment precision and laminating tolerance worsen
Solution Approach 1:
The patent combines the metal plate and display module into a single laminated assembly that is cut together in one operation. This merging ensures that both components maintain perfect alignment and matching edge profiles, eliminating cumulative tolerance errors that would occur with separate cutting operations.
Solution Approach 2:
The patent uses the laminated bonding between metal plate and display module as an intermediary that holds both components in fixed relative positions during cutting. This intermediary connection ensures that both parts are cut with identical precision along the same path, achieving perfect alignment without requiring separate positioning operations.
3Strength
If the etching depth is increased to at least half the thickness, then the structural integrity and folding capability are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies different etching depths to different regions of the metal plate: deeper etching in folding areas to enable bending, and controlled etching in non-folding areas to maintain structural integrity. This localized quality variation achieves both folding capability and strength without requiring uniformly complex manufacturing throughout the entire plate.
Solution Approach 2:
The patent changes the etching depth parameter across different regions of the metal plate, with etching depth reaching at least half the plate thickness in critical areas. This parameter variation optimizes both structural integrity and folding performance while managing manufacturing complexity through controlled depth modulation rather than uniform deep etching.
Data Source
AI summary
A method of manufacturing a display device includes defining an etching line having a shape of a closed curve on a metal plate having a rigidity higher than a rigidity of a display panel, etching the metal plate along the etching line, laminating the etched metal plate to a display module including the display panel, defining a cutting line corresponding to the etching line, and cutting the display module and the metal plate laminated to the display module together with each other along the cutting line.