Display Module Laser Through-Hole Machining With Staged Cooling
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Solution Overview
Problem
Existing display module manufacturing methods face challenges in achieving reliable through-hole formation due to thermal deformation issues, leading to increased heat-affected zones and potential defects.
Innovation Solution
A laser machining method involving multiple irradiation processes with varying time intervals and power levels, specifically targeting layers with different thermal deformation temperatures, to minimize heat accumulation and prevent defects by allowing for heat diffusion between irradiation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single continuous laser irradiation process is used to form through-holes, then the manufacturing process is simple and fast, but thermal deformation and heat-affected zones increase leading to defects
Solution Approach 1:
The continuous laser irradiation process is divided into multiple discrete irradiation steps with intermediate cooling periods. The laser beam irradiates the through-hole boundary in segments, pausing between segments to allow heat diffusion, thereby reducing thermal accumulation and heat-affected zones while maintaining manufacturing efficiency
Solution Approach 2:
The laser irradiation is applied periodically rather than continuously, with alternating irradiation and cooling phases. This periodic action allows the material to dissipate heat between laser pulses, preventing thermal deformation and defects while still achieving through-hole formation at acceptable speeds
2Loss of time
If high laser power is used to quickly form through-holes, then the manufacturing time is reduced, but thermal deformation temperature is exceeded causing defects
Solution Approach 1:
The laser operates in periodic pulses with controlled duty cycles, delivering high power in brief intervals followed by cooling periods. This allows sufficient energy delivery for rapid through-hole formation while preventing temperature from exceeding the thermal deformation threshold through intermittent operation
Solution Approach 2:
The laser irradiation parameters are pre-configured with specific power levels and timing sequences tailored to the thermal properties of each layer. By preliminarily setting the irradiation schedule before processing, the system prevents thermal deformation while maintaining efficient through-hole formation
3Productivity
If laser irradiation is applied without time intervals between steps, then the manufacturing process is continuous and efficient, but heat accumulates creating larger heat-affected zones
Solution Approach 1:
The continuous manufacturing process is segmented into discrete irradiation steps separated by controlled time intervals. These segments allow heat to diffuse during pauses, reducing the heat-affected zone area while maintaining overall manufacturing efficiency through optimized segment timing
Solution Approach 2:
The laser processing parameters are dynamically adjusted by introducing time interval variations between irradiation steps. By changing the temporal parameters of the process, heat accumulation is controlled and heat-affected zones are minimized without significantly compromising manufacturing 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
This approach enhances the reliability of the display module by reducing the area of the heat-affected zone and minimizing defects, thereby improving the manufacturing process and product reliability.
Implementation Method 1
forming a through-hole in the display module includes performing a first irradiation process of irradiating a first laser beam along a first boundary defining the through-hole, performing a second irradiation process of irradiating a second laser beam along a second boundary after the performing of the first irradiation process
Implementation Method 2
Existing display module manufacturing methods face challenges in achieving reliable through-hole formation due to thermal deformation issues
Implementation Method 3
irradiating a first laser beam along a first boundary defining the through-hole
Data Source
AI summary
A method for manufacturing a display module includes preparing a display module comprising a plurality of layers and forming a through-hole in the display module. The forming the through-hole includes performing a first irradiation process of irradiating a first laser beam along a first boundary defining the through-hole, performing a second irradiation process of irradiating a second laser beam along a second boundary after the first irradiation process, and performing a third irradiation process of irradiating a third laser beam along a third boundary after the second irradiation process. A time interval between the first irradiation process and the second irradiation process may be different from a time interval between the second irradiation process and the third irradiation process.