Display Panel Stamping for Narrow Bezel Manufacturing

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Solution Overview

Problem

The challenge is to reduce the bezel area in display panels while maintaining a wide display area, as existing methods like laser removal of materials can generate particles, delaying the process and increasing failure rates.

Innovation Solution

A method involving forming a circuit element layer and a display element layer on a substrate, removing inorganic layers using stamping to create sub-opening grooves, and coupling substrates to form a working panel, which is then cut into portions, with optional laser treatment and filling layers to enhance light transmittance and reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If laser is used to remove organic material or inorganic material to form holes, then hole formation is achieved, but particles are generated causing process delay

Engineering Contradiction:

Improvehole formation processVSAvoidprocess speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces the laser-based removal method with a mechanical stamping process. The stamping process uses physical contact and pressure to remove inorganic layers and form sub-opening grooves, eliminating the particle generation issue associated with laser ablation while maintaining efficient hole formation capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and removes specific inorganic layers (such as pixel defining layers and electrode layers) through the stamping process to create sub-opening grooves. This selective removal approach allows precise control over what materials are removed and where, preventing unwanted particle generation and enabling continuous processing

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If laser is used to remove material to form holes, then hole formation is achieved, but failure rate increases

Engineering Contradiction:

Improvehole formation processVSAvoidmanufacturing failure rate

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a stamping tool as an intermediary mechanism between the substrate and the material removal process. This intermediary allows controlled, clean removal of inorganic layers without the uncontrolled vaporization and particle generation that occurs with laser ablation, thereby reducing manufacturing failures

Inventive Principle:

Principle #24Intermediary (Mediator)

3Area of stationary object

If bezel area is reduced to widen display area, then display area increases, but manufacturing complexity increases

Engineering Contradiction:

Improvedisplay areaVSAvoidmanufacturing process complexity

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

The patent segments the hole formation process into multiple stages: first forming opening grooves, then forming sub-opening grooves within those openings. This segmentation allows different manufacturing techniques to be applied at different stages, simplifying the overall process while achieving the desired narrow bezel and wide display area configuration

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent performs preliminary actions by first forming the opening grooves and then using those openings as templates for the subsequent sub-opening groove formation. This preliminary structuring simplifies the second stage of processing and enables precise control over the final hole positions and sizes, making the reduced bezel design manufacturable

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 effectively reduces bezel area, minimizes failure rates, and enhances operational reliability by improving light transmittance and structural integrity of the display panel.

Implementation Method 1

removing at least one inorganic layer of the display element layer formed in the first sub-opening groove by stamping to define a second sub-opening groove

Methodology Applied

Scientific EffectMechanical pressure: Mechanical Force

Implementation Method 2

irradiating the hole area with a laser to remove a layer exposed by the second sub-opening groove to define a third sub-opening groove

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 3

the light emitting element may include an organic light emitting diode

Methodology Applied

Scientific EffectElectroluminescence: Electroluminescence

Data Source

PatentUS11127931B2Method for manufacturing display panel

Publication Date: 2021.09.21 SAMSUNG DISPLAY CO LTD

AI summary

A method for manufacturing a display panel includes forming a circuit element layer including a transistor on a plurality of cell areas of a first working substrate. Each of the cell areas includes a hole area on which at least one first sub-opening groove on which the circuit element layer is not formed is located. The method further includes forming a display element layer including a light emitting element on the plurality of cell areas, removing at least one inorganic layer of the display element layer formed in the first sub-opening groove by stamping to define a second sub-opening groove, coupling the first working substrate to a second working substrate to define a working panel, and cutting the working panel into portions corresponding to the plurality of cell areas.