Flexible Display Substrate Alignment via Simultaneous Film Cutting
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Solution Overview
Problem
Existing display panel manufacturing methods face challenges in achieving precise alignment and zero tolerance between flexible substrates, leading to increased production errors and complexity in assembling flexible display devices with slim bezel designs.
Innovation Solution
A method involving the simultaneous cutting and lamination of optical clear adhesive films and touch panels with display substrates to form flexible substrates, ensuring edge portion alignment and reducing tolerance, thereby simplifying the assembly process and improving production yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple flexible substrates are attached separately and cut individually, then each substrate can be processed independently, but alignment precision and tolerance between substrates deteriorate
Solution Approach 1:
The patent merges multiple flexible substrates (display substrate, touch panel substrate, adhesive film) into a single integrated structure by attaching them together before cutting. This combining approach allows all substrates to be cut simultaneously along the same cutting line, ensuring precise alignment and consistent bezel width across all layers, thereby resolving the alignment precision problem while maintaining manufacturing efficiency
2Reliability
If substrates are cut separately after individual assembly, then each substrate maintains its own tolerances, but cumulative tolerance errors increase and bezel area cannot be reduced
Solution Approach 1:
The patent applies preliminary action by attaching all flexible substrates together before the cutting process. This sequence ensures that the cutting operation is performed on a pre-assembled unit, allowing tolerance control to be established at the cutting stage rather than accumulating through multiple separate assembly operations. The preliminary attachment creates a unified structure where a single cutting line defines the bezel area for all substrates simultaneously
3Productivity
If traditional separate attachment and cutting methods are used, then manufacturing processes are simpler, but production errors increase and assembly complexity increases
Solution Approach 1:
The patent combines multiple substrates into an integrated assembly before cutting, which reduces production errors by ensuring all layers are cut along the exact same line. This merging approach eliminates misalignment errors that would occur with separate cutting operations. Although the attachment step adds a process step, it reduces downstream rework and assembly errors, thereby improving overall manufacturing efficiency and productivity
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 method enhances the alignment of flexible substrates, reduces production errors, and allows for a slim bezel design in flexible display devices, improving manufacturing efficiency and cost-effectiveness.
Implementation Method 1
Cutting the first and second films may include using a laser beam or pressure.
Implementation Method 2
Applying a heat to the second film to allow the first film to be adhered to the display substrates and the second film.
Data Source
AI summary
A method of manufacturing a display panel, including providing a plurality of display substrates spaced apart from each other by a predetermined area disposed therebetween when viewed in a plan view, each of the display substrates including a display area, on which an image is displayed, and each of the display substrates being flexible; attaching a first film onto the display substrates to overlap with the display substrates; attaching a second film onto the first film; and substantially and simultaneously cutting the first and second films along a cutting line defined in an area overlapping with the predetermined area.