Display Panel Manufacturing via Annular Groove Substrate Removal
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Solution Overview
Problem
The existing methods for manufacturing display panels, which involve cutting notches for image acquisition assemblies, often damage the base substrate, leading to low yield rates and increased manufacturing costs due to the difficulty in achieving a high screen-to-body ratio without compromising the integrity of the panel.
Innovation Solution
A method that forms a base structure in a target region on a base substrate, followed by creating an annular groove in the display structure layer where the base structure is exposed, allowing the base structure to be removed without cutting the substrate, thereby creating a transparent region for the image acquisition assembly without damaging the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If a notch is formed on the base substrate by cutting process to accommodate image acquisition assembly, then the screen-to-body ratio is improved, but the base substrate integrity is damaged and yield rate decreases
Solution Approach 1:
The base substrate is segmented into two regions: a target region where the base structure is removed to create transparency for image acquisition, and a non-target region where the base substrate remains intact. This segmentation allows the image acquisition assembly to be positioned without compromising the overall integrity of the base substrate, thus resolving the contradiction between screen-to-body ratio and substrate integrity.
Solution Approach 2:
The base structure is selectively removed only in the target region while maintaining its presence in other regions. This local modification creates the necessary transparency for image acquisition in the target region while preserving the structural integrity and functionality of the base substrate in non-target regions, thereby achieving both high screen-to-body ratio and maintained substrate integrity.
2Area of moving object
If cutting process is used to form notch for image acquisition assembly, then screen-to-body ratio is improved, but manufacturing cost increases due to low yield rate
Solution Approach 1:
The base structure is formed in the target region before forming the display structure layer. This preliminary formation allows for precise control and selective removal of the base structure without requiring subsequent cutting operations that would damage the completed display panel, thereby improving yield rate and reducing manufacturing costs while maintaining high screen-to-body ratio.
Solution Approach 2:
The base structure in the target region is selectively extracted or removed after the display structure layer is formed. This extraction creates the necessary transparency for image acquisition without requiring cutting operations on the finished panel, thus avoiding yield loss and reducing manufacturing costs while achieving high screen-to-body ratio.
3Reliability
If base structure is removed to create transparent region, then transparency for image acquisition is improved, but display structure layer separation becomes necessary
Solution Approach 1:
The manufacturing process is segmented into distinct steps: forming the base structure in the target region, forming the display structure layer, creating an annular groove to expose the base structure, and selectively removing the base structure. This segmentation allows for controlled separation of the display structure layer in the target region while maintaining simplicity in each individual step, achieving transparency without excessive overall complexity.
Data Source
AI summary
Disclosed is a method for manufacturing a display panel including: forming a base structure in a target region on a base substrate; forming a display structure layer on the base substrate on which the base structure is formed; forming an annular groove in the display structure layer in a region which an orthographic projection of the base structure on the display structure layer falls within, the base structure being exposed in the annular groove; and removing the base structure surrounded by the annular groove to separate the display structure layer surrounded by the annular groove from the base substrate.