Flexible Display Substrate Laser Cutting and Particle Removal
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Solution Overview
Problem
The manufacturing of flexible display devices faces challenges with defects caused by foreign particles generated during the cutting process of the substrate, leading to electrical connections among pad electrodes and reduced usable area due to dummy areas between cell areas.
Innovation Solution
A method involving the use of a first laser beam to cut the substrate and a second laser beam with a shorter wavelength to remove foreign particles, creating a stepwise recess portion that prevents conductive carbonized material from remaining, ensuring pad electrodes remain insulators and eliminating dummy areas between cell areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a first laser beam is used to cut the substrate, then cutting efficiency is improved, but foreign particles are generated causing electrical connections among pad electrodes
Solution Approach 1:
The patent applies a second laser beam with shorter wavelength to irradiate the cutting surface, converting the harmful foreign particles (conductive carbonized material) generated by the first laser beam into beneficial removed debris. This eliminates the electrical connection risk while preserving the efficient cutting function of the first laser beam.
Solution Approach 2:
The second laser beam with shorter wavelength provides concentrated energy that accelerates the oxidation and removal of conductive carbonized material from the cutting surface, effectively eliminating foreign particles that would otherwise cause electrical connections between pad electrodes.
2Manufacturing precision
If dummy areas are provided between cell areas, then manufacturing precision is improved, but usable area of the substrate is reduced
Solution Approach 1:
The patent extracts and removes the unnecessary dummy areas between cell areas by implementing precise cutting control and secondary laser irradiation that eliminates the need for safety margins, thereby maximizing the usable area of the substrate while maintaining cutting precision.
Solution Approach 2:
The patent changes the wavelength parameter of the laser beam (using a second laser with shorter wavelength) to achieve more precise cutting and better removal of conductive material, allowing elimination of dummy areas while maintaining manufacturing precision.
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 approach significantly reduces driving defects by maintaining pad electrodes as insulators and increases the usable area of the flexible substrate by eliminating unnecessary space between cell areas, thereby enhancing productivity.
Implementation Method 1
cutting the main substrate and the passivation film by irradiating a first laser beam on an edge of the cell areas
Implementation Method 2
removing foreign particles generated by the first laser beam by irradiating a second laser beam on an edge of the first side
Data Source
AI summary
A flexible display device includes a flexible substrate that includes a first side; a display unit disposed in a first region of the first side and that includes a plurality of pixels; and a pad portion disposed in a second region of the first side and that includes a plurality of pad electrodes. The flexible substrate includes a stepwise recess portion disposed along an edge of the first side on which end portions of the pad electrodes are provided.