Flexible Display Support Member Laser Edge Trimming
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Solution Overview
Problem
Flexible display devices face challenges in manufacturing due to issues with support member alignment and impact distribution, leading to potential defects and lamination errors, especially when the end surface of the support member is not properly positioned on the virtual plane of the display panel.
Innovation Solution
A method of manufacturing a display device involving the formation of a preliminary display panel with dummy areas, attachment of a support member with varying thicknesses and cross-sectional shapes, and laser irradiation to remove edge portions and dummy areas simultaneously, ensuring the support member's end surface is aligned with the display panel's end surface, thereby distributing impact and preventing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the support member has uniform thickness throughout, then manufacturing is simpler, but impact distribution and structural robustness are compromised
Solution Approach 1:
The support member employs varying thickness across different regions: a first thickness in the first dummy area, a second thickness in the active display area, and a third thickness in the second dummy area. This local quality variation allows the support member to provide enhanced support where needed (improving reliability) while maintaining manufacturability through controlled thickness transitions.
2Reliability
If the support member extends beyond the display panel boundaries, then impact distribution is improved, but alignment precision and lamination accuracy deteriorate
Solution Approach 1:
The support member is designed with dummy areas that extend beyond the display panel boundaries before final assembly. These dummy areas provide preliminary support and alignment reference during the manufacturing and assembly process, ensuring precise alignment. After assembly, the excessive portions are removed, leaving the support member perfectly aligned with the display panel while having previously provided extended support for impact distribution.
3Manufacturing precision
If the support member has excessive material in dummy areas, then alignment and support are improved, but material waste and device weight increase
Solution Approach 1:
The support member is initially formed with excessive material in the dummy areas to facilitate alignment and support during manufacturing. After the display panel is assembled and positioned, the excessive portions of the support member are removed through a cutting process. This discarding of excess material achieves precise alignment and reduces material waste, while the support member retains sufficient material in critical areas to maintain structural integrity and impact distribution.
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 improves the yield of display devices by preventing defects and lamination errors, ensuring robustness and reducing sagging, while maintaining a lightweight design by optimizing the thickness and shape of the support member's edge and central portions.
Implementation Method 1
removing an edge portion of the preliminary support member positioned around the second dummy area by irradiating a laser onto the preliminary support member, and forming a display panel and a support member having an end surface positioned on a virtual plane including an end surface of the display panel by irradiating another laser onto the preliminary support member, and by concurrently removing the first dummy area of the preliminary display panel and the second dummy area of the preliminary support member
Data Source
AI summary
A method of manufacturing a display device includes forming a preliminary display panel including a light-emitting element on a substrate, and having a first dummy area at an outermost portion, attaching a preliminary support member under the preliminary display panel and having a second dummy area overlapping the first dummy area, removing an edge portion of the preliminary support member positioned around the second dummy area by irradiating a laser onto the preliminary support member, and forming a display panel and a support member having an end surface positioned on a virtual plane including an end surface of the display panel by irradiating another laser onto the preliminary support member, and by concurrently removing the first dummy area of the preliminary display panel and the second dummy area of the preliminary support member.