Flexible Display Terminal Structure for Clean Laser-Cut Edges

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Solution Overview

Problem

Existing laser cutting methods for flexible display panels leave carbide residues on the cut end surfaces, which can reduce the electrical resistance and integrity of the terminal portions.

Innovation Solution

The flexible display panel design includes an inclined surface with a width of at least 13.1 μm on the terminal portion, formed by laser cutting with a defocused technique, followed by dry cleaning with fine particles to remove carbide residues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If laser cutting is used to process the terminal portion, then cutting efficiency is improved and stress during cut is reduced, but carbide remains on the cut end surface

Engineering Contradiction:

Improvecutting efficiencyVSAvoidcut end surface cleanliness

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by forming an inclined surface at the terminal portion before laser cutting. This pre-formed geometry allows the laser to cut more effectively while preventing carbide adhesion, as the inclined surface enables carbide to fall off rather than remain on the cut end surface.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes geometric parameters by creating an inclined surface with a specific angle (30-60 degrees) and width (10 μm or more) at the terminal portion. This parameter modification fundamentally changes how carbide behaves during and after laser cutting, transforming it from a problematic residue into removable material.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If mechanical blade is used for cutting, then manufacturing process is simple, but stress during cut increases causing cracks

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidcrack prevention

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces the mechanical blade cutting system with a laser cutting system. This substitution eliminates the mechanical contact that causes stress concentration and cracking, using optical energy instead to perform the cutting operation with minimal mechanical stress on the flexible substrate.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If laser cutting is used, then crack prevention is improved, but carbide residue on cut surface occurs

Engineering Contradiction:

Improvecrack preventionVSAvoidcut end surface cleanliness

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The inclined surface is formed in advance before laser cutting to create a geometry that prevents carbide adhesion. This preliminary geometric preparation ensures that when laser cutting occurs, any carbide generated will naturally fall off the inclined surface rather than adhering to the cut end surface.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent converts the potentially harmful carbide residue into a beneficial situation by using the inclined surface geometry. The carbide that would normally be a problem is transformed into removable material that falls off the inclined surface, turning a defect into a self-cleaning mechanism.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 effectively prevents carbide residues from adhering to the cut end surfaces, maintaining high electrical resistance and structural integrity of the terminal portions, while simplifying the manufacturing process.

Implementation Method 1

A scribe apparatus with a mechanical blade or a laser apparatus (laser processing apparatus) is used to process a terminal portion or other components of the flexible display panel during manufacturing

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

An example of the process includes cutting. A laser apparatus may be used instead of a scribe apparatus to execute a laser cutting process in the flexible display panel

Methodology Applied

Scientific EffectLaser cutting: Laser Ablation

Implementation Method 3

cleaning, by dry cleaning, an inclined surface formed in the cutting

Methodology Applied

Scientific EffectDry cleaning:

Data Source

PatentUS12364117B2Flexible display panel and manufacturing method of flexible display panel

Publication Date: 2025.07.15 MAGNOLIA BLUE CORP

AI summary

Provided is a flexible display panel including a display portion for display and a terminal portion around the display portion, in which each of the display portion and the terminal portion includes a flexible substrate including a first main surface and a second main surface on an opposite side of the first main surface, the flexible substrate containing resin, and a wiring layer formed on the first main surface of the flexible substrate, the terminal portion includes an inclined surface inclined toward the display portion from the second main surface side to the first main surface side, and a width of the inclined surface in plan view of the flexible display panel is equal to or greater than 13.1 μm.