Display Panel Laser Cutting for Haze Edge Reduction
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Solution Overview
Problem
Current display devices face challenges in efficiently manufacturing display panels with precise angled surfaces and minimal haze areas, which affect the display's optical performance and structural integrity.
Innovation Solution
The display device incorporates a display panel with a support film and a polarizing film, where the side surfaces of these films are inclined at specific angles relative to the panel's surfaces, and a laser cutting method is used to form the display units by irradiating the panel with varying laser beam intensities, creating controlled haze areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cutting methods are used to separate display units, then manufacturing process is simple, but large haze areas are generated affecting optical performance
Solution Approach 1:
The cutting process is divided into multiple passes with different laser beam intensities. The first pass uses high intensity to create an initial cut, and subsequent passes use lower intensities to complete the separation. This segmentation of the cutting process enables precise control of haze area generation while maintaining manufacturing feasibility.
Solution Approach 2:
The laser beam is applied periodically in multiple passes rather than continuously. Each pass is separated by controlled intervals, allowing the material to respond to each intensity level independently. This periodic application of cutting energy enables precise haze area control that would be impossible with a single continuous cutting operation.
2Productivity
If laser beam with high intensity is used for cutting, then cutting speed is fast, but large haze areas are generated
Solution Approach 1:
The high-intensity laser cutting is segmented into multiple passes. The first pass uses high intensity for rapid material removal and fast cutting speed, while subsequent passes use progressively lower intensities to complete the cut with minimal haze generation. This segmentation allows the system to capture the speed benefit of high intensity without suffering its harmful haze effects.
Solution Approach 2:
The first laser pass applies excessive cutting action with high intensity to rapidly remove material and achieve fast cutting speed. Subsequent passes apply partial action with reduced intensity to finish the cut precisely. This approach allows the system to benefit from the speed of excessive action while correcting the haze problem through controlled partial actions.
3Strength
If films are attached at right angles to the panel surface, then manufacturing is simple, but structural integrity is compromised
Solution Approach 1:
The films are attached at asymmetric angles (first angle for the first film, second angle for the second film) rather than uniformly at right angles. This asymmetric angular arrangement optimizes the structural integrity of the display unit by distributing mechanical stresses more effectively, while the angles remain simple enough to maintain ease of manufacture.
4Manufacturing precision
If multiple laser passes are used to reduce haze, then optical performance improves, but manufacturing time increases
Solution Approach 1:
The laser cutting is performed in periodic passes with optimized intervals. Each pass is spaced to allow the material to respond appropriately to the previous pass, maximizing the efficiency of each cutting action. This periodic structure achieves precise haze control while minimizing the total time required compared to non-periodic or overly frequent passes.
Solution Approach 2:
The first laser pass applies excessive cutting action to rapidly remove the majority of material, reducing the workload for subsequent passes. This partial completion strategy allows later passes to focus solely on haze control rather than material removal, significantly reducing the total manufacturing time while maintaining precision.
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 allows for the precise cutting of display panels with reduced haze areas, enhancing the display's optical performance and structural integrity while minimizing bezel width.
Implementation Method 1
irradiating a laser beam on the display mother substrate from the first mother film to cut the display mother substrate into the display units
Implementation Method 2
irradiating the laser beam with a first intensity... irradiating the laser beam with a second intensity less than the first intensity
Data Source
AI summary
A display device includes a display panel, a first film, and a polarizing film. The display panel includes a first surface, a second surface opposite to the first surface, and a side surface. The first film is beneath the first surface of the display panel. The polarizing film is on the second surface of the display panel. The polarizing film has a haze area including a yellow area extending along an edge of the polarizing film in a plan view.