Flexible Display Panel Edge Patterning for Laser Cutting
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Solution Overview
Problem
Flexible display panels face issues during laser cutting, where the formation of conductive particles from the flexible substrate and metal layer can cause short circuits and defects, such as burns and abnormal images, due to the carbonization and sputtering of materials near the cutting line.
Innovation Solution
A manufacturing method for display panels involves forming a flexible substrate and switch array layer on a glass substrate, patterning the switch array layer to exclude the edge area, and removing thin film layers from the edge area to prevent the formation of conductive particles during cutting, ensuring the metal wire is not short-circuited.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser cutting is used to cut the flexible substrate, then the flexible display panel can be separated from the glass substrate, but conductive particles are formed due to carbonization and sputtering, causing short circuits and defects
Solution Approach 1:
The patent removes the flexible substrate and metal layer from the edge area before laser cutting. This extraction of potentially harmful materials prevents them from forming conductive particles during the cutting process, thereby maintaining electrical insulation reliability while preserving cutting efficiency.
Solution Approach 2:
The patent applies preliminary anti-action by removing the flexible substrate and metal layer before the harmful effect (conductive particle formation) can occur. This preventive measure eliminates the source of carbonization and sputtering, ensuring that no conductive particles are generated during subsequent laser cutting.
2Stability of the object's composition
If the flexible substrate and metal layer are present near the cutting line, then the complete display structure is maintained, but conductive particles cause short circuits and abnormal images
Solution Approach 1:
The patent extracts the flexible substrate and metal layer from the edge area, removing the materials that would otherwise generate harmful conductive particles during laser cutting. This extraction maintains structural integrity in the functional areas while eliminating the harmful factor at the cutting zone.
Solution Approach 2:
The patent applies local quality by creating a differentiated structure: the display area maintains complete layers for functional integrity, while the edge area has removed layers to prevent harmful particle formation. This localized modification ensures that each area has the appropriate material composition for its specific function.
3Ease of manufacture
If the edge area retains thin film layers, then the manufacturing process is simplified, but the flexible substrate and metal layer form conductive particles during cutting
Solution Approach 1:
The patent extracts the flexible substrate and metal layer from the edge area, eliminating the source of conductive particles. This targeted removal prevents short circuits during laser cutting while minimizing additional manufacturing complexity by limiting the removal to only the necessary edge region.
Solution Approach 2:
The patent performs preliminary removal of the flexible substrate and metal layer from the edge area before the laser cutting process. This preliminary action prevents the formation of conductive particles, addressing the harmful factor before it can manifest during the subsequent cutting operation.
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 prevents the formation of conductive particles during cutting, thereby avoiding short circuits and ensuring the integrity of the display panel, maintaining image quality and preventing defects like burns and poor lines.
Implementation Method 1
the flexible substrate near the cutting line 15 is carbonized and sputtered to the welding area 102
Implementation Method 2
the flexible substrate near the cutting line 15 is carbonized and sputtered to the welding area 102
Implementation Method 3
When laser cutting, the flexible substrate near the cutting line 15 is carbonized and sputtered to the welding area 102, so as to be cooled and solidified to form conductive particles 17
Data Source
AI summary
A display panel and a manufacturing method thereof are provided. The method includes: forming a flexible substrate on a display area and a welding area of a glass substrate; sequentially forming a switch array layer and an organic light-emitting display layer on the flexible substrate and an edge area of the glass substrate; patterning the switch array layer, such that a switching element and a metal wire are respectively formed on the display area and the welding area, and a portion of the switch array layer and the organic light-emitting display layer on the edge area are removed.