Display Panel Substrate Cutting and Polishing
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Solution Overview
Problem
The manufacturing process of display panels faces inefficiencies due to the need for precise cutting and polishing of both curved and straight portions, which results in excessive tool abrasion and reduced productivity, as well as a decrease in the usage life of polishing tools.
Innovation Solution
A method involving separate cutting and polishing processes for straight and curved portions using distinct tools, where straight lines are cut and polished with a cutting wheel and curve portions are cut with a laser, and both edges are polished using specific tools to form a step at the boundary, optimizing tool usage and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single polishing tool is used for both straight and curved portions, then device complexity is reduced, but tool abrasion increases and usage life decreases
Solution Approach 1:
The patent divides the polishing process into two distinct segments: one for straight portions and another for curved portions. Different polishing tools are assigned to each segment based on their specific geometric requirements, thereby reducing overall tool abrasion and extending usage life despite increased process complexity.
Solution Approach 2:
The patent applies different polishing characteristics to different portions of the display panel. Straight portions receive polishing from a first tool optimized for linear surfaces, while curved portions receive polishing from a second tool optimized for curved surfaces, ensuring optimal performance for each local region.
2Manufacturing precision
If excessive polishing is performed on both straight and curved portions, then cutting quality is improved, but productivity decreases and tool usage life reduces
Solution Approach 1:
The patent segments the polishing operation into two distinct processes with different parameters and tool types. This allows each process to be optimized for its specific portion, achieving high manufacturing precision without requiring excessive polishing that would reduce productivity.
Solution Approach 2:
The patent changes polishing parameters such as tool type, polishing pressure, and motion pattern according to the specific portion being polished. Straight portions use parameters optimized for linear surfaces while curved portions use different parameters, achieving high quality with minimal material removal and maximum efficiency.
3Device complexity
If the same cutting tool is used for both straight and curved portions, then device complexity is reduced, but cutting precision for both portions deteriorates
Solution Approach 1:
The patent divides the cutting process into two distinct operations: one for straight portions and another for curved portions. Each operation uses a tool specifically suited for its geometric requirements, ensuring high cutting precision for both portion types despite increased process complexity.
Solution Approach 2:
The patent applies different cutting characteristics to different portions of the display panel. Straight portions are cut using a first tool optimized for linear cuts, while curved portions are cut using a second tool optimized for curved paths, ensuring optimal cutting precision for each local 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 reduces tool abrasion, increases tool usage life, and enhances work efficiency by allowing precise and quick polishing of complex curve shapes while minimizing abrasion on polishing tools, thereby improving the manufacturing process for display panels.
Implementation Method 1
cutting the curve portion by a second cutting process using a second tool that is different from the first tool... cutting off the curve portion by using a laser
Data Source
AI summary
A method of manufacturing a display panel includes forming a unit panel which includes a display unit provided on a substrate. The substrate of the unit panel is cut out in a form of a closed loop having a straight line portion and a curve portion that are connected to each other. The cutting out of the substrate of the unit panel includes cutting the straight line portion by a first cutting process using a first tool and cutting the curve portion by a second cutting process using a second tool that is different from the first tool.