Flexible Display Panel Inclined Edge Cutting Without Stage Damage
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Solution Overview
Problem
Existing methods for cutting the rim of flexible panels in flexible display apparatuses are inefficient and can damage the supporting stage, leading to increased costs and reduced productivity.
Innovation Solution
A method involving laser cutting along a closed-curve cutting line from the second protection film to the first adhesion layer, allowing for simultaneous removal of the dummy unit and first protection film, while minimizing damage to the stage and enabling the formation of an inclined edge with a gradually increasing width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cutting methods are used to cut the rim of flexible panels, then the panel can be cut to desired shape, but the supporting stage is damaged leading to increased costs and reduced productivity
Solution Approach 1:
The patent replaces conventional mechanical cutting methods with laser cutting technology. The laser beam precisely cuts the flexible panel along the cutting line without physical contact, eliminating mechanical stress and damage to the supporting stage while maintaining high cutting precision for the panel shape
Solution Approach 2:
The patent introduces a release film as an intermediary layer between the flexible panel and the supporting stage. This release film prevents direct adhesion between the panel and stage, allowing the panel to be cut and removed without damaging the stage surface, thus protecting stage integrity while enabling precise cutting
2Manufacturing precision
If conventional cutting methods are used, then cutting can be performed, but productivity is reduced due to stage damage and increased costs
Solution Approach 1:
The patent replaces mechanical cutting with laser cutting, which operates faster and more efficiently. The laser beam can continuously cut along complex paths without the setup time and maintenance requirements of mechanical cutters, significantly improving manufacturing efficiency while maintaining high cutting accuracy
Solution Approach 2:
The patent designs a universal supporting stage with a release film coating that can accommodate multiple different flexible panel cutting operations. The stage can be reused for various panel shapes and sizes without damage or recalibration, improving overall manufacturing efficiency through multi-functionality
3Manufacturing precision
If the cutting depth extends to the first adhesion layer, then separation of display and non-display regions is achieved, but the first protection film may be damaged
Solution Approach 1:
The patent extracts or removes the first protection film from the flexible panel after laser cutting. By separating the protection film removal step from the cutting process, the cutting can extend to the adhesion layer for precise separation without the risk of damaging the protection film during cutting, as the film is removed in a controlled subsequent step
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 enhances productivity and reduces manufacturing costs by preventing stage damage and allowing the use of a universal stage for various specifications, while ensuring efficient separation of display and non-display regions.
Implementation Method 1
The cutting of the flexible panel may include irradiating a laser along the closed-curve cutting line from a side of the second protection film
Implementation Method 2
A cutting groove formed by the laser may have a space gradually reducing towards the first adhesion layer from the second protection film
Implementation Method 3
The stage may include a suction hole, and the fixing of the flexible panel on the stage may include attaching the flexible panel to the stage by applying suction force to the flexible panel through the suction hole
Data Source
AI summary
A method of manufacturing a display apparatus includes preparing a panel with a panel layer displaying images, a first protection film on a first surface of the panel layer with a first adhesion layer, and a second protection film on a second surface of the panel layer with a second adhesion layer, disposing the panel on a stage, cutting the panel on the stage along a closed-curve line to a predetermined depth extending from the second protection film to at least a portion of the first adhesion layer, and separating a first portion of the panel inside the closed-curve line from a second portion of the panel outside the closed-curve line, such that the second portion is removed simultaneously with the entire first protection film according to a first boundary by the line and a second boundary between the panel layer and the first protection film.