Flexible Display Panel Substrate Cutting and Polarizer Attachment

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Solution Overview

Problem

Flexible substrates in display panels face challenges during cutting due to film shrinkage or warping, leading to difficult separation and poor bonding yield of circuit boards.

Innovation Solution

A manufacturing method for display panels involves attaching polarizers to substrates before cutting, using specific cutting lines to form notches that expose bonding areas, thereby preventing film shrinkage and warping and improving the bonding yield of circuit boards.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the substrate is flexible and not stiff enough, then the display panel can achieve flexible form factors, but film shrinkage or film warping occurs during cutting

Engineering Contradiction:
Improveflexible form factorVSAvoidcutting precision
Core Design Contradiction:
Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The method applies preliminary action by performing the cutting operation before the substrate is fully assembled with all components. By cutting the substrate while it is still in a less constrained state, the flexible substrate experiences reduced stress and minimal shrinkage or warping during the cutting process, thereby maintaining manufacturing precision while preserving flexibility.

Inventive Principle:
Principle #10Preliminary action

2Ease of operation

If the substrate is cut to expose bonding pads, then circuit board bonding is enabled, but film shrinkage or warping causes difficult separation or poor operation

Engineering Contradiction:
Improvebonding pad accessibilityVSAvoidsubstrate separation difficulty
Core Design Contradiction:
Ease of operationVSEase of manufacture

Solution Approach 1:

The cutting operation is performed as a preliminary step before final assembly and bonding. By exposing the bonding pads through cutting earlier in the manufacturing process, the substrate can be separated and positioned more easily, avoiding the difficulties that would arise from attempting to cut and separate flexible substrates after full assembly.

Inventive Principle:
Principle #10Preliminary action

3Manufacturing precision

If polarizers are attached before cutting, then film shrinkage and warping are prevented, but the manufacturing process complexity increases

Engineering Contradiction:
Improvesurface flatnessVSAvoidmanufacturing process complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The manufacturing method merges multiple operations into a more efficient sequence: polarizers are attached to the substrate, then cutting is performed, and finally bonding pads are exposed. This combined approach actually reduces overall process complexity compared to performing these operations separately, as it prevents film shrinkage and warping that would require additional corrective steps, thereby maintaining surface flatness while streamlining the manufacturing process.

Inventive Principle:
Principle #5Merging (Combining)

Data Source

PatentUS20240411166A1Display panel and manufacturing method thereof
Publication Date: 2024.12.12 HANNSTAR DISPLAY CORP
  • US20240411166A1 patent drawing
  • US20240411166A1 patent drawing
  • US20240411166A1 patent drawing

AI summary

A display panel, including a first substrate, a second substrate, a liquid crystal layer, a first polarizer, a second polarizer, and a circuit board, is provided. The first substrate has a display area and a bonding area outside the display area. The second substrate overlaps with the first substrate and exposes the bonding area. The liquid crystal layer is disposed between the first substrate and the second substrate, and overlaps with the display area. The first polarizer is disposed on a surface of the first substrate facing away from the second substrate. The second polarizer is disposed on a surface of the second substrate facing away from the first substrate. The circuit board is bonded to the bonding area. A first side wall of the second substrate facing the bonding area is flush with a second side wall of the second polarizer facing the bonding area.