Display Panel Perforation Using Laser Cooling for Hole Precision
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Solution Overview
Problem
The challenge in manufacturing display devices is that laser irradiation during the manufacturing process can generate heat, which damages adjacent components and compromises the integrity of the display device, particularly in the non-active areas where driving circuits and wiring are located.
Innovation Solution
A method is developed where a first hole is perforated in the active area, and a second larger hole is formed by laser irradiation surrounding the first hole, with the laser area spaced apart to minimize heat damage, allowing for the alignment of electronic modules like camera modules, and including features such as an antireflective layer, adhesive layer, and light shielding layers to protect the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser irradiation is used to form holes in the display panel, then manufacturing precision and hole quality are improved, but heat is generated that damages adjacent components and compromises display device integrity
Solution Approach 1:
A cooling gas flow is introduced as an intermediary between the laser beam and the display panel components. The gas flow carries away heat generated during laser irradiation, preventing thermal damage to adjacent components while allowing the laser to effectively form holes in the display panel.
Solution Approach 2:
The patent changes the physical state and flow parameters of the cooling gas (pressure, flow rate, temperature) to optimize heat removal efficiency. By adjusting these parameters, the system maintains effective laser hole formation while minimizing thermal damage to surrounding components.
2Adaptability or versatility
If a larger second hole is formed by laser irradiation surrounding the first hole, then electronic modules like camera modules can be aligned and integrated, but heat generation increases risking damage to driving circuits and wiring in the non-active area
Solution Approach 1:
Cooling gas flow serves as a mediator that protects heat-sensitive driving circuits and wiring in the non-active area during laser irradiation. The gas flow is directed to surround the laser path, creating a protective thermal barrier that enables formation of larger holes for electronic module integration without damaging adjacent circuits.
Solution Approach 2:
The laser irradiation is applied in a controlled, periodic manner with cooling gas flow continuously active during the process. This periodic laser action with continuous cooling allows progressive formation of the second hole while maintaining thermal safety for surrounding components.
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 effectively reduces thermal damage to the display device by managing heat emission through the residual area, enabling precise alignment and integration of electronic modules while maintaining the integrity of the display panel components.
Implementation Method 1
the laser area is spaced apart from the first hole by an intervening residual area
Implementation Method 2
A method is developed where a first hole is perforated in the active area, and a second larger hole is formed by laser irradiation surrounding the first hole, with the laser area spaced apart to minimize heat damage
Data Source
AI summary
A display device manufacturing method is provided including a display module in which an active area and a non-active area surrounding the active area are defined. A first hole is perforated having a first diameter on the active area. A second hole is formed having a second diameter by irradiating a laser area at least partially surrounding the first hole with a laser. The second diameter is larger than the first diameter.