Irregular Display Panel Laser Cutting to Protect Circuit Structures
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Solution Overview
Problem
The current laser cutting method for forming irregularly-shaped display panels often damages electronic devices in circuit structures due to thermal energy sputtering, leading to reduced product reliability and yield.
Innovation Solution
The method involves forming laser cutting trajectories with entry and exit points that do not overlap with the irregularly-shaped boundaries of the display panel, ensuring that the laser cutting path avoids the edges and minimizes thermal energy refraction or reflection onto internal devices, thereby preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If laser cutting is performed entering from edge positions of the rectangular display panel, then the irregularly-shaped display panel can be formed, but thermal energy sputtering damages electronic devices in circuit structures
Solution Approach 1:
The patent applies preliminary action by pre-planning the laser cutting trajectory to avoid edge positions before cutting occurs. The trajectory is designed such that the laser enters and exits at positions that do not overlap with the irregularly-shaped boundary, preventing thermal energy sputtering from reaching circuit structures beforehand
Solution Approach 2:
The patent introduces an intermediary concept by using a virtual boundary layer or safety zone between the laser cutting path and the irregularly-shaped boundary. This intermediary space acts as a buffer that prevents direct interaction between the laser's thermal energy and the circuit structures, thereby protecting electronic devices
2Productivity
If laser cutting path passes through edge positions, then cutting can be completed, but light path refraction and reflection cause thermal energy to fly out and produce sputtering
Solution Approach 1:
The patent applies local quality by making the laser cutting trajectory locally adaptive to the panel's geometry. Instead of a uniform cutting approach, the trajectory is specifically designed to avoid edge positions where refraction and reflection occur, while still achieving complete cutting separation of the irregularly-shaped display panel
3Manufacturing precision
If laser cutting trajectory overlaps with irregularly-shaped boundary, then cutting precision is achieved, but circuit structures in non-display region are damaged
Solution Approach 1:
The patent uses preliminary action by pre-defining a safe cutting trajectory that maintains an offset distance from the irregularly-shaped boundary. This preliminary trajectory design ensures that cutting precision is achieved while preventing harmful thermal energy from reaching circuit structures in the non-display region
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 significantly reduces the risk of laser energy sputtering and improves the product ratio and reliability by ensuring that the cutting process does not interfere with internal devices, resulting in a more reliable and efficient formation of irregularly-shaped display panels.
Implementation Method 1
A laser cutting method is usually used to cut the rectangular display panel. The laser cutting process produces a large thermal energy.
Implementation Method 2
A light path of the laser may be refected and/or refracted when the laser passes the edge positions of the rectangular display panel
Implementation Method 3
A light path of the laser may be refected and/or refracted when the laser passes the edge positions of the rectangular display panel
Data Source
AI summary
Irregularly-shaped display panel and cutting method are provided. The display panel includes a display region and a non-display region surrounding the display region. The non-display region includes at least one irregularly-shaped boundary. The irregularly-shaped display panel further includes a substrate and the substrate includes a base substrate. The non-display region includes laser cutting trajectories. An orthographic projection of each of the laser cutting trajectories to the base substrate at least partially overlaps an orthographic projection of a corresponding irregularly-shaped boundary. Each of the laser cutting trajectories includes a cutting entry point and a cutting exit point at two ends thereof, and at least one of the cutting entry point and the cutting exit point does not overlap the orthographic projection of the corresponding irregularly-shaped boundary. The laser cutting trajectories are used as a laser cutting path.