Display Panel Resin Cutting with Hydrophobic Blade Coating
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Solution Overview
Problem
Existing manufacturing processes for display devices suffer from process defects such as burrs and residue formation during the cutting of resin layers, which can lead to inefficiencies and quality issues.
Innovation Solution
An apparatus and method involving a guide plate, cutting member, plasma treatment, and hydrophobic coating are used to cut resin layers on display panels, ensuring perpendicular alignment and minimizing residue adhesion, utilizing a cutting member coated with a hydrophobic material like octadecyltrichlorosilane to prevent burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a cutting member is used to cut the resin layer, then the resin layer can be separated along the edge of the display panel, but residue of the resin layer adheres to the cutting member causing burr formation and process defects
Solution Approach 1:
A hydrophobic coating is applied as an intermediary layer on the cutting member surface. This coating acts as a mediator between the cutting member and the resin layer, reducing adhesive force and preventing direct contact that causes residue adhesion and burr formation, while still allowing effective cutting to occur
Solution Approach 2:
The surface properties of the cutting member are changed by applying a hydrophobic coating. This parameter change modifies the surface energy and adhesion characteristics, making the cutting member surface less attractive to the resin layer material, thereby reducing residue adhesion while maintaining cutting functionality
2Productivity
If the cutting member cuts the resin layer, then the resin layer is separated, but burrs are formed on the side surface of the resin layer
Solution Approach 1:
The hydrophobic coating serves as a mediator that allows the cutting member to cut through the resin layer efficiently while preventing the formation of burrs on the side surface. The coating reduces friction and adhesive forces that would otherwise cause material deformation and burr formation during the cutting process
Solution Approach 2:
The patent replaces a purely mechanical cutting approach with a combination of hydrophobic coating technology and mechanical cutting. This substitution of the cutting member surface properties with a hydrophobic layer enables cleaner cutting action that prevents burr formation while maintaining cutting efficiency
3Reliability
If a hydrophobic coating is applied to the cutting member, then residue adhesion and burr formation are reduced, but the device complexity increases
Solution Approach 1:
Instead of changing the fundamental structure or complexity of the cutting device, the patent applies a hydrophobic coating that modifies the surface parameters of the cutting member. This parameter change approach improves cutting quality and reduces residue adhesion without significantly increasing the overall device complexity
Solution Approach 2:
The cutting member is transformed into a composite structure by combining the original cutting material with a hydrophobic coating layer. This composite approach leverages the cutting properties of the base material and the non-stick properties of the hydrophobic coating, achieving improved reliability without substantial complexity increase
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
The solution effectively prevents burr formation and residue adhesion, ensuring precise cutting and reducing process defects, thereby enhancing the manufacturing efficiency and quality of display devices.
Implementation Method 1
a plasma treatment part which performs a plasma treatment on the cutting member
Implementation Method 2
a second tank which accommodates a hydrophobic coating solution for coating the cutting member with a hydrophobic material
Implementation Method 3
coating the cutting member with a hydrophobic material
Data Source
AI summary
An apparatus for manufacturing a display device includes: a guide plate provided to contact a display panel; a cutting member which cuts a resin layer formed on the display panel along an edge of the display panel; a first tank which accommodates a cleaning solution for removing a residue of the resin layer adhered to the cutting member; a plasma treatment part which performs a plasma treatment on the cutting member; and a second tank which accommodates a hydrophobic coating solution for coating the cutting member with a hydrophobic material.