Laser-Cut Display Panel Seams for Seamless Curved Surfaces

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Solution Overview

Problem

Existing display technologies face challenges in creating seamless and high-resolution large display regions with minimal visible seams between overlapping display panels, particularly in curved surfaces, where traditional cutting methods result in noticeable boundaries and degrade display quality.

Innovation Solution

The use of laser processing to cut and align display panels, forming step-like boundaries that are less noticeable, and the application of polarizing films to minimize seam visibility, along with high-pressure bonding to ensure a smooth and bubble-free interface, allows for the creation of large, seamless display surfaces with improved optical clarity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional physical blade cutting is used to cut display panels, then the cutting process is simple and fast, but the boundaries between overlapping panels are noticeable and display quality degrades

Engineering Contradiction:

Improveboundary visibilityVSAvoidcutting process complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical blade cutting with laser processing to cut display panels. This substitution eliminates the noticeable boundaries and seam degradation associated with mechanical cutting, as laser processing creates cleaner, more precise cuts that result in less visible seams when panels are overlapped.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies laser processing with specific parameters (laser type, power, speed, focal position) to achieve precise cutting depth control. By adjusting these parameters, the cutting depth is optimized to create step-like boundaries that are less noticeable, thereby improving manufacturing precision without significantly increasing process complexity.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If display panels are cut deeper to reduce seam visibility, then boundary visibility improves, but air bubbles are generated during bonding

Engineering Contradiction:

Improveseam visibilityVSAvoidair bubble generation

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent optimizes laser processing parameters including cutting depth, laser power, and scanning speed to achieve the optimal balance between seam visibility and air bubble generation. By precisely controlling these parameters, the cutting depth is adjusted to create step-like boundaries that reduce seam visibility while minimizing void formation during bonding.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies partial cutting depth rather than complete thickness cutting. The laser processes only a portion of the panel thickness to create step-like boundaries, which is sufficient to reduce seam visibility without cutting deep enough to generate excessive air bubbles during bonding.

Inventive Principle:

Principle #16Partial or excessive action

3Area of stationary object

If multiple display panels are assembled to create large display regions, then the display area increases, but the number of boundaries and seams increases

Engineering Contradiction:

Improvedisplay region sizeVSAvoidseam visibility

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The patent divides the large display region into multiple separate display panels that are assembled together. Each panel is individually processed with laser cutting to create step-like boundaries, and when assembled, these processed edges create less noticeable seams compared to traditional cutting methods, thereby maintaining display quality across the entire large display region.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces traditional mechanical assembly methods with laser-processed panel edges for joining multiple display panels. The laser-processed step-like boundaries enable better alignment and reduced visible seams when panels are assembled, allowing for larger display regions with maintained manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enables the production of high-resolution, seamless display apparatus with reduced seam visibility, allowing for larger display regions on curved surfaces without compromising display quality, and reduces the generation of air bubbles during bonding.

Implementation Method 1

the periphery of end surfaces of a plurality of display panels is processed by laser light

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

the application of polarizing films to minimize seam visibility

Methodology Applied

Scientific EffectPolarization: Polarisation

Data Source

PatentUS20220384398A1Display Apparatus and Manufacturing Method of Display Apparatus

Publication Date: 2022.12.01 SEMICON ENERGY LAB CO LTD

AI summary

A novel display apparatus that is highly convenient or reliable is provided. Alternatively, a novel input/output device that is highly convenient or reliable is provided. The display apparatus is configured in the following manner: the periphery of end surfaces of a plurality of display panels is processed by laser light and the display panels are joined together so that unevenness is not generated at a boundary between the adjacent display panels and the outermost surface of the display apparatus is flat.