Flexible Display Substrate Slit Design for Cutting Burr Prevention
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Solution Overview
Problem
During the cutting process of flexible display substrates, burrs and distortions around the cutting lines can lead to layer detachment or cracking, resulting in line disconnections and reduced reliability of the display device. Additionally, remaining metal films in stepped portions can cause shorts when electrically coupled to circuit board lines.
Innovation Solution
A display device design that includes a central area with a display area on a substrate, a peripheral area around the central area, and a slit formed by removing a portion of the insulating material between insulating patterns in the peripheral area. This design helps prevent shorts and enhances reliability by managing the metal films and substrate layers effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the display substrate is cut by physical pressure using a press, then the substrate can be separated into individual display devices, but regions around the cutting lines become burred or distorted causing layer detachment or cracking
Solution Approach 1:
The substrate is divided into multiple individual display devices through cutting lines. The invention segments the continuous substrate into discrete units while managing the structural integrity at the boundaries through specific layer configurations and cutting techniques.
Solution Approach 2:
Different regions of the substrate have different structural characteristics. The peripheral area around cutting lines is treated differently from the central display area, with specific attention to layer removal and structural reinforcement in the cutting regions to prevent burr formation and layer detachment.
2Reliability
If layers around the cutting lines are removed to expose the substrate, then layer detachment is prevented, but remaining metal films in stepped portions can cause shorts when coupling the circuit board
Solution Approach 1:
Metal films and insulating layers are selectively removed from the peripheral areas around cutting lines to prevent layer detachment. The invention extracts these potentially problematic layers while carefully managing the remaining structures to avoid short circuits during circuit board coupling.
Solution Approach 2:
The invention introduces intermediate structural elements and processes between layer removal and circuit board coupling. This includes controlled exposure of substrate regions and management of remaining metal film configurations to serve as intermediaries that prevent both detachment and short circuits.
3Weight of moving object
If the display substrate is made thin and flexible, then impact resistance and portability are improved, but the substrate becomes more susceptible to damage during cutting and handling
Solution Approach 1:
The invention utilizes the flexible substrate's inherent properties while managing its vulnerabilities. The thin flexible substrate provides weight reduction and impact resistance, but the invention adds specific structural considerations during manufacturing to compensate for the reduced durability during cutting and handling processes.
Data Source
AI summary
A display device includes: a central area having a display area on a substrate; and a peripheral area around the central area; a plurality of pads arranged along one direction in the central area; a plurality of insulating patterns adjacent the plurality of pads; and a slit between the plurality of insulating patterns in the peripheral area, wherein the slit is formed by removing at least a portion of an insulating material of the plurality of insulating patterns.