Foldable Display Shock Absorber Cutting to Minimize Carbonization

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Solution Overview

Problem

During the manufacture of foldable display devices, laser cutting of the polymer base layer can cause heat generation, leading to carbonization and adverse effects on the device's folding and reliability.

Innovation Solution

The method involves performing laser cutting at high speed with low energy density, applying the laser multiple times, and using a synchronized laser oscillator to minimize the carbonized region, while physically tearing off the shock absorber's outer surface to reduce damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If laser cutting is performed on the polymer base layer during manufacture, then the display device can be fabricated with precise dimensions, but heat is generated causing carbonization that adversely affects folding and reliability

Engineering Contradiction:
Improvecutting precisionVSAvoidfolding reliability
Core Design Contradiction:
Manufacturing precisionVSReliability

Solution Approach 1:

The laser cutting process is divided into multiple sequential passes instead of a single high-energy cut. Each pass removes a portion of the material with lower energy density, preventing excessive heat accumulation and carbonization while achieving the desired cut depth and precision through cumulative effect.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The laser oscillation is performed periodically with controlled duty cycles, alternating between active cutting phases and pause phases that allow heat dissipation. This periodic action prevents continuous heat buildup in the polymer base layer, reducing carbonization and maintaining material integrity for reliable folding.

Inventive Principle:
Principle #19Periodic action

2Productivity

If high energy density laser is used for cutting, then the cutting speed can be increased improving productivity, but the carbonized region becomes larger damaging the polymer base layer

Engineering Contradiction:
Improvecutting speedVSAvoidcarbonized region size
Core Design Contradiction:
ProductivityVSObject-affected harmful factors

Solution Approach 1:

Instead of using excessive high energy density in a single pass, the method applies partial action through multiple low-energy passes. Each pass contributes to the overall cutting depth without exceeding the energy threshold that causes severe carbonization, achieving sufficient cutting speed while minimizing damage through cumulative partial removal.

Inventive Principle:
Principle #16Partial or excessive action

Solution Approach 2:

The laser beam rapidly oscillates back and forth along the cutting path, spending minimal time at each location. This rushing through approach delivers the necessary cumulative energy for cutting while preventing localized overheating and carbonization by continuously moving the energy input along the cut line rather than concentrating it.

Inventive Principle:
Principle #21Skipping (Rushing through)

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 minimizes the carbonized region and heat-related damage, enhancing the folding reliability and overall performance of the display device.

Implementation Method 1

when the polymer base layer is irradiated with a laser, heat is generated by the laser irradiation

Methodology Applied
Scientific EffectLaser irradiation: Laser

Implementation Method 2

heat is generated by the laser irradiation, thereby forming a carbonized region

Methodology Applied
Scientific EffectHeat generation: Heating

Data Source

PatentUS11775020B2Display device and method of manufacturing the same
Publication Date: 2023.10.03 SAMSUNG DISPLAY CO LTD
  • US11775020B2 patent drawing
  • US11775020B2 patent drawing
  • US11775020B2 patent drawing

AI summary

A display device includes a display panel including a first surface, and a shock absorber disposed on the first surface of the display panel, the shock absorber having a second surface thereof facing the first surface, wherein, in a first cross-section taken in a thickness direction of the shock absorber, the shock absorber includes an edge surface having a first point closest to the first surface and a second point farthest from the first surface, on an outer surface of the shock absorber, and based on an imaginary line extending between the first and second surfaces, a first distance between the imaginary line and the first point is less than a second distance between the imaginary line and the second point.