Foldable Display Laser Cutting to Minimize Bezel Dead Space
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Solution Overview
Problem
Current display devices have significant dead space due to the bezel size, which hinders their compactness and flexibility, especially in foldable or bendable designs.
Innovation Solution
A method of manufacturing a display device that involves a preliminary foldable module with a support plate, panel protective layer, and window module, using a dual-laser cutting process to minimize dead space by cutting the support plate and subsequent layers with varying laser beam intensities, allowing for integral cutting and reduced step sizes between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional single-laser cutting method is used, then the manufacturing process is simple, but the dead space is large and compactness is reduced
Solution Approach 1:
The cutting process is segmented into two distinct operations: a first cutting operation that cuts the support plate with a first laser beam, and a second cutting operation that cuts the panel protective layer, display panel, and window module with a second laser beam. This segmentation allows each laser beam to be optimized for its specific material, reducing dead space while maintaining manufacturing feasibility
Solution Approach 2:
The patent changes laser beam parameters by using two different laser beams with different characteristics. The first laser beam is optimized for cutting the support plate, while the second laser beam is optimized for cutting the panel protective layer, display panel, and window module. This parameter change enables precise cutting with minimal dead space
2Area of stationary object
If dual-laser cutting process is used, then dead space is reduced and compactness is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the cutting of multiple different materials (support plate, panel protective layer, display panel, window module) into a single integrated manufacturing process. By combining the first and second cutting operations in one工艺流程, the process achieves reduced dead space while maintaining reasonable manufacturing complexity through systematic integration
3Speed
If high intensity laser beam is used for cutting, then cutting speed is fast, but the step between layers increases
Solution Approach 1:
The patent applies local quality by using different laser beams for different materials. The first laser beam is specifically optimized for cutting the support plate, while the second laser beam is optimized for cutting the panel protective layer, display panel, and window module. This localized optimization ensures both cutting speed and precision for each material type, minimizing layer steps
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 effectively reduces dead space and enhances the compactness and flexibility of display devices by ensuring precise cutting with minimal steps between layers, improving the overall design and functionality of foldable or bendable displays.
Implementation Method 1
Performing a first cutting operation including cutting the support plate with a first laser beam
Implementation Method 2
Performing a second cutting operation of sequentially cutting the panel protective layer, the display panel, and the window module with the second laser beam
Implementation Method 3
Detecting, by a laser-sensing part, reflected light that is reflected from a surface of the panel protective layer exposed by cutting the support plate
Data Source
AI summary
A method of manufacturing a display device includes preparing a preliminary foldable module including a window module, a display panel disposed on the window module, a panel protective layer disposed on the display panel, and a support plate disposed on the panel protective layer. Performing a first cutting operation including cutting the support plate with a first laser beam. Detecting, by a laser-sensing part, reflected light that is reflected from a surface of the panel protective layer exposed by cutting the support plate and changing the first laser beam to a second laser beam. Performing a second cutting operation of sequentially cutting the panel protective layer, the display panel, and the window module with the second laser beam.