Laser Beam Splitting for Maskless Display Pad Bonding
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Solution Overview
Problem
In the manufacturing of display panels, the large size of the laser spot leads to heat diffusion beyond the bonding area, reducing yield and requiring masks with array-type transparent holes to block unwanted regions, which decreases laser light utilization.
Innovation Solution
A laser light source system using a collimator lens and a diffractive optical component to generate multiple sub-beams that only irradiate the pads and light emitting components, eliminating the need for masks and minimizing unnecessary irradiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a mask with array-type transparent holes is disposed on the laser optical path to block regions outside the pads, then heat diffusion is prevented, but laser light utilization rate is reduced
Solution Approach 1:
The patent segments the single laser beam into multiple sub-beams using a diffractive optical component, with each sub-beam precisely targeting individual pads. This eliminates the need for masks while preventing heat diffusion to non-target areas, as each sub-beam is independently directed only where needed.
Solution Approach 2:
The patent changes the spatial distribution parameters of the laser beam by using a diffractive optical component to create multiple focused sub-beams at different positions. This transforms the energy distribution from a single large spot to multiple precise spots, maintaining high laser utilization while preventing heat diffusion to unwanted regions.
2Area of stationary object
If the laser spot size is large to cover bonding areas, then bonding coverage is sufficient, but heat diffuses to regions outside pads reducing yield
Solution Approach 1:
The patent divides the large laser spot into multiple smaller sub-beams, each precisely targeting individual pads and light emitting components. This segmentation allows sufficient bonding coverage across multiple locations while preventing heat diffusion to non-bonding regions, thereby maintaining high yield.
Solution Approach 2:
The patent transitions from a single-dimensional large spot approach to a multi-dimensional array of focused sub-beams. By distributing energy across multiple spatial points simultaneously, the system achieves comprehensive bonding coverage without the heat diffusion problems associated with large single spots.
3Device complexity
If a single laser beam is used to irradiate all pads, then device complexity is low, but processing time increases reducing productivity
Solution Approach 1:
The patent segments the laser beam into multiple sub-beams using a diffractive optical component, enabling simultaneous irradiation of multiple pads. This increases productivity by processing multiple bonding locations in parallel while maintaining relatively simple system complexity through the use of standard optical components.
Solution Approach 2:
The patent combines multiple functions into a single optical path: the diffractive optical component simultaneously performs beam splitting, spatial distribution, and focusing for multiple pads. This merging of functions increases productivity without significantly increasing device complexity.
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 reduces laser light waste, increases productivity by reducing processing time, and maintains high laser light utilization without compromising energy efficiency.
Implementation Method 1
The collimator lens is disposed on a path of the laser beam to generate a collimated beam
Implementation Method 2
The diffractive optical component is disposed on a path of the collimated beam to generate a plurality of sub beams
Implementation Method 3
The display substrate is disposed on a focal plane of the refractive component, so as to utilize the sub beams to simultaneously irradiate the pads on the display substrate and the light emitting components
Data Source
AI summary
A laser light source system is used to simultaneously irradiate a plurality of pads on a display substrate and a plurality of light emitting components. The laser light source system includes a laser light source, a collimator lens, a diffractive optical component and a refractive component. The laser light source is configured to provide a laser beam. The collimator lens is disposed on a path of the laser beam to generate a collimated beam. The diffractive optical component is disposed on a path of the collimated beam to generate a plurality of sub beams. The display substrate is disposed on a focal plane of the refractive component, so as to utilize the sub beams to bond the light emitting components to the pads.