Dummy Pattern Absorbs Laser Heat in Display Panel Cutting
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Solution Overview
Problem
The manufacturing process of display devices faces challenges in efficiently cutting panel substrates without damaging the base substrate, particularly when overlapping laser beams are applied, leading to potential cracking due to thermal stress.
Innovation Solution
Incorporating dummy patterns with materials like molybdenum at strategic points on the panel substrate, which have a high melting temperature and thermal expansion coefficient matching the base substrate, to absorb and reflect laser heat, minimizing thermal stress and preventing damage during the cutting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser beams are applied to cut the panel substrate, then cutting efficiency is improved, but thermal stress causes cracking of the base substrate
Solution Approach 1:
A dummy pattern consisting of a first dummy pattern and a second dummy pattern is disposed at a boundary between the panel area and the peripheral area. The dummy pattern acts as an intermediary that absorbs and reflects laser heat, preventing the laser beams from directly heating the base substrate at the cutting point, thus avoiding thermal stress and cracking while maintaining cutting efficiency.
Solution Approach 2:
The dummy pattern is specifically designed to absorb and reflect laser heat that would otherwise cause harmful thermal stress to the base substrate. By converting the harmful laser energy into heat absorbed by the dummy pattern (which has high melting temperature and appropriate thermal expansion coefficient), the harmful effect is transformed into a protective mechanism that prevents cracking.
2Reliability
If dummy patterns are added to prevent cracking, then base substrate protection is improved, but device structure complexity increases
Solution Approach 1:
The dummy pattern is designed with specific material parameters (high melting temperature and thermal expansion coefficient matching the base substrate) to achieve protection functionality. By carefully selecting and controlling these parameters, the dummy pattern provides effective protection while maintaining structural simplicity and avoiding excessive complexity.
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 dummy patterns effectively absorb and reflect laser heat, preventing damage to the base substrate and enabling precise cutting of panel substrates without cracking, thus improving the manufacturing efficiency and quality of display devices.
Implementation Method 1
the dummy pattern overlaps a point at which a plurality of laser beams intersect when viewed on a plane... the dummy patterns effectively absorb and reflect laser heat
Implementation Method 2
the dummy pattern overlaps a point at which a plurality of laser beams intersect when viewed on a plane... the dummy patterns effectively absorb and reflect laser heat
Implementation Method 3
A method for manufacturing a display device includes providing a base substrate including a panel area and a peripheral area around the panel area. A pixel layer is formed on the panel area. A dummy pattern is formed on a boundary between the panel area and the peripheral area. A protection part is disposed on the panel area and the peripheral area. The protection part is irradiated with a laser beam to overlap an outline of the panel area.
Data Source
AI summary
A method for manufacturing a display device includes providing a panel substrate including a panel area, a peripheral area, and a dummy pattern disposed at a boundary between the panel area and the peripheral area. A protection part is disposed on the panel substrate. A first processing line overlaps a first outline of the panel area extending from a first point of an outline of the panel area. A second processing line overlaps a second outline extending from the first point in a direction different from the first outline are defined. The protection part is partially cut along the first processing line. The protection part is fully cut along the second processing line. The dummy pattern overlaps the first point.