Laser Cutting Display Panel Dummy Film Sagging

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Solution Overview

Problem

During the manufacturing of display devices, the cutting areas sag due to gravity when laser light is irradiated, leading to inaccurate cutting, which affects the yield ratio of the display device.

Innovation Solution

A method involving a display panel divided into cutting areas and a body part, with a dummy film attached to the bottom surface, where laser light is irradiated along a cutting line to create a groove in the dummy film, allowing for accurate separation and removal of the cutting areas without sagging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If laser light is irradiated to cut the cutting area, then the cutting area is removed to provide holes for functional elements, but the cutting area sags due to gravity causing inaccurate cutting

Engineering Contradiction:

Improvecutting processVSAvoidcutting accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

A dummy film is attached to the back surface of the display panel before laser cutting begins. This preliminary action provides structural support to the cutting area throughout the cutting process, preventing sagging caused by gravity and maintaining cutting accuracy without requiring additional support structures during the actual cutting operation.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If the cutting area is removed to provide holes for functional elements, then functional elements can be exposed externally, but the yield ratio decreases due to cutting inaccuracies

Engineering Contradiction:

Improvefunctional element integrationVSAvoidyield ratio

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The dummy film is attached in advance to prevent cutting inaccuracies, ensuring that functional elements can be properly integrated while maintaining high yield ratio by eliminating defects caused by sagging during the cutting process.

Inventive Principle:

Principle #10Preliminary action

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 improves the accuracy of cutting areas, enhancing the yield ratio of the display device by preventing sagging and ensuring precise removal of cutting areas.

Implementation Method 1

cutting the cutting area by irradiating laser light toward a cutting line defined as a boundary between the cutting area and the body part

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

irradiating the laser light to a groove line of the dummy film, which overlaps the cutting line, to define a groove in the dummy film along the groove line

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS10910596B2Method of manufacturing a display device by laser cutting an area of a display panel

Publication Date: 2021.02.02 SAMSUNG DISPLAY CO LTD

AI summary

In a method for manufacturing a display device, the method includes: providing a display panel divided into a cutting area and a body part surrounding the cutting area; attaching a dummy film on a bottom surface of the display panel; cutting the cutting area by irradiating laser light toward a cutting line defined as a boundary between the cutting area and the body part; irradiating the laser light to a groove line of the dummy film, which overlaps the cutting line, to define a groove in the dummy film along the groove line; and separating the dummy film from the body part.