Flexible Display Panel Inclined Edge Cutting Without Stage Damage
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Solution Overview
Problem
The existing methods for manufacturing flexible display apparatuses are inefficient in cutting the rim of flexible panels to desired shapes, leading to potential damage to the cutting stage and increased production costs due to the need for multiple stages for different specifications.
Innovation Solution
A method involving a closed-curve cutting process using a laser along a predetermined depth that stops before reaching the first protection film, allowing simultaneous removal of the dummy unit and protection film, while forming an inclined edge with a polarizing layer, and using a suction stage to secure the panel, which minimizes stage damage and allows for a single stage to be used across various specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the cutting depth extends through the entire panel thickness to remove the dummy unit, then the dummy unit is completely removed, but the cutting stage is damaged due to deep laser cutting
Solution Approach 1:
The cutting process is segmented into two distinct stages: first, a shallow cut is made to a predetermined depth that stops before reaching the first protection film; second, the dummy unit and first protection film are simultaneously removed by peeling. This segmentation allows complete dummy unit removal without damaging the cutting stage, as the laser does not need to cut through the entire panel thickness.
Solution Approach 2:
A shallow cutting groove is formed in advance to a predetermined depth that extends from the second protection film to at least a portion of the first adhesion layer, but stops before reaching the first protection film. This preliminary action creates a separation path that enables subsequent removal of the dummy unit and first protection film without requiring deep cutting that would damage the stage.
2Manufacturing precision
If multiple cutting stages are used for different panel specifications, then cutting precision is improved, but manufacturing cost increases
Solution Approach 1:
The cutting method is designed to be universally applicable to flexible panels of various specifications. By using a standardized shallow cutting depth that stops before the first protection film, the same cutting stage can process panels with different dummy unit sizes and shapes, eliminating the need for multiple specialized stages while maintaining cutting precision.
Solution Approach 2:
The method changes the cutting parameter from deep cutting (through entire thickness) to shallow cutting (predetermined depth before first protection film). This parameter change enables a single cutting stage to handle various panel specifications by adjusting only the cutting path (closed-curve cutting line) rather than requiring multiple stages with different cutting depths.
3Ease of manufacture
If deep cutting is used to separate the dummy unit, then separation is achieved, but production efficiency decreases due to stage damage and replacement needs
Solution Approach 1:
The method replaces deep mechanical laser cutting with a combination of shallow laser cutting and mechanical peeling. The laser creates a shallow cutting groove to a predetermined depth, and then the dummy unit and first protection film are removed by peeling force. This substitution eliminates stage damage from deep cutting while achieving complete separation, thereby maintaining production efficiency.
4Ease of manufacture
If the cutting line reaches the first protection film, then complete separation is achieved, but the first protection film is damaged requiring separate handling
Solution Approach 1:
The shallow cutting groove is formed in advance to a predetermined depth that stops before reaching the first protection film. This preliminary action creates a separation path without damaging the first protection film, allowing it to remain intact for subsequent handling and ensuring complete dummy unit removal through peeling without additional protection film repair steps.
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 method enhances productivity by allowing a single stage to be used for multiple specifications, reduces manufacturing costs, and prevents stage damage by limiting the cutting groove depth, thereby improving the efficiency and cost-effectiveness of flexible display apparatus production.
Implementation Method 1
The cutting of the flexible panel may include irradiating a laser along the closed-curve cutting line from a side of the second protection film
Implementation Method 2
A cutting groove formed by the laser may have a space gradually reducing towards the first adhesion layer from the second protection film
Implementation Method 3
The stage may include a suction hole, and the fixing of the flexible panel on the stage may include attaching the flexible panel to the stage by applying suction force to the flexible panel through the suction hole
Data Source
AI summary
A method of manufacturing a display apparatus includes preparing a panel with a panel layer displaying images, a first protection film on a first surface of the panel layer with a first adhesion layer, and a second protection film on a second surface of the panel layer with a second adhesion layer, disposing the panel on a stage, cutting the panel on the stage along a closed-curve line to a predetermined depth extending from the second protection film to at least a portion of the first adhesion layer, and separating a first portion of the panel inside the closed-curve line from a second portion of the panel outside the closed-curve line, such that the second portion is removed simultaneously with the entire first protection film according to a first boundary by the line and a second boundary between the panel layer and the first protection film.