Display Panel Edge Grinding for Crack Prevention
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Solution Overview
Problem
The manufacturing process of display panels often results in fine cracks on the edges of substrates, which can compromise the rigidity and integrity of the panels, leading to potential damage and reduced strength.
Innovation Solution
The implementation of a method that involves creating a display panel with chamfered or slanted edges by grinding portions of the substrate, and applying a protection unit including an adhesive and cerium dioxide, diamond, or silicon carbide on the thin-film encapsulation layer to enhance strength and prevent crack formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the substrate is cut into multiple portions after manufacturing display panels, then productivity is improved, but fine cracks are generated on the edges reducing rigidity
Solution Approach 1:
The patent applies preliminary action by forming the inclined surface on the substrate edge before the cutting process. This pre-treatment modifies the edge geometry in advance to prevent crack generation during subsequent cutting operations. The inclined surface is created through grinding or polishing before the substrate is divided into multiple portions, thereby eliminating the root cause of edge cracks that would otherwise occur during cutting.
2Ease of manufacture
If the substrate edges are left flat after cutting, then manufacturing simplicity is maintained, but crack formation and growth are promoted reducing panel durability
Solution Approach 1:
The patent applies local quality by modifying only the edge region of the substrate while leaving the main body unchanged. The inclined surface is formed specifically at the edges where cracks typically initiate, without affecting the overall substrate structure or requiring changes to the manufacturing process for the entire panel. This localized modification maintains manufacturing simplicity while significantly improving crack resistance at the vulnerable edge regions.
3Strength
If protection units are applied on the thin-film encapsulation layer, then edge strength is enhanced, but device complexity increases
Solution Approach 1:
The patent applies composite materials by combining the protection unit with the thin-film encapsulation layer to form a composite protective structure. The protection unit, which may include adhesive layers and protective films, is integrated with the encapsulation layer to create a multi-layer composite structure that enhances edge strength. This composite approach provides improved mechanical protection while maintaining a relatively simple overall device architecture.
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 effectively prevents the formation and growth of cracks, enhances the rigidity of the display panel, and minimizes damage from external impacts by dispersing stress across the edges, thereby improving the panel's durability and reducing failure rates during and after manufacturing.
Implementation Method 1
forming a slanting surface inclined with respect to the first surface or the second surface by grinding an edge of the first surface or an edge of the second surface
Data Source
AI summary
Systems and methods are described for a display panel and a method of manufacturing the display panel. The systems and methods may provide for a substrate having a first surface and a second surface that face each other, a display unit including an organic light-emitting device arranged on the first surface of the substrate; and a thin-film encapsulation layer arranged on the display unit to shield the display unit, wherein an edge of the first surface or an edge of the second surface are inclined with respect to the first surface or the second surface. The inclined surfaces are designed to prevent damage to the display due to fine cracks during the manufacturing process as the display panel is trimmed or cut from a single base member. A display panel having improved strength characteristics may be manufactured, as well.