Laser-Cut Polarizing Layer for Zero-Bezel Display

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Solution Overview

Problem

Conventional display devices face limitations in minimizing bezels due to the step between the polarizing layer and the display panel, which affects immersion and light leakage, especially in high-resolution and large-sized displays.

Innovation Solution

A method involving the use of laser cutting and polishing to eliminate the step between the polarizing layer and the display panel, followed by attaching a conductive film and patterning it using laser beams to form ultra-fine conductive patterns for side bonding, allowing for a zero-bezel design and improved electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the polarizing layer is attached to the display panel, then the display function is achieved, but a step is formed between the polarizing layer and the display panel causing light leakage and reduced immersion

Engineering Contradiction:

Improvedisplay functionVSAvoidlight leakage

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and removes the problematic step structure between the polarizing layer and display panel by using laser cutting to create a recess in the polarizing layer that matches the protrusion of the display panel, eliminating the light leakage issue while maintaining the display function

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent transitions from a planar attachment to a three-dimensional recess structure by cutting into the polarizing layer, creating a stepped configuration that eliminates light leakage while maintaining optical functionality

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Length of stationary object

If the bezel width is reduced for high-resolution displays, then immersion is improved, but the step between polarizing layer and display panel causes light leakage

Engineering Contradiction:

Improvebezel widthVSAvoidlight leakage

Core Design Contradiction:

Length of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The patent removes the light leakage problem by extracting the step structure through laser cutting, creating a recess in the polarizing layer that eliminates the harmful light leakage while allowing minimal bezel width for high immersion

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent performs preliminary laser cutting and polishing of the polarizing layer before final assembly, pre-forming the recess structure to prevent light leakage issues before the display is completed

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If conventional cutting methods are used for the polarizing layer, then manufacturing is simple, but cutting precision and surface quality are insufficient

Engineering Contradiction:

Improvecutting processVSAvoidcutting precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces conventional mechanical cutting methods with laser cutting technology, substituting mechanical contact with optical energy to achieve precise cutting and polishing of the polarizing layer with superior surface quality and dimensional accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of operation

If the conductive film is attached to the side surface, then electrical connections are enabled, but adhesive strength may be insufficient

Engineering Contradiction:

Improveelectrical connectionVSAvoidadhesive strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent changes the physical and chemical parameters of the conductive film attachment process, including surface treatment, adhesive composition, temperature, and pressure parameters, to optimize both electrical connection quality and adhesive strength simultaneously

Inventive Principle:

Principle #35Parameter changes

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 creation of high-resolution displays with reduced bezels, enhanced adhesive strength, and improved electrical connections, facilitating the production of ultra-high definition displays with increased process reliability and efficiency.

Implementation Method 1

patterning the conductive film using a second laser beam

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

cutting the polarizing layer using a first laser beam

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS11385495B2Display device and method of manufacturing the same

Publication Date: 2022.07.12 SAMSUNG DISPLAY CO LTD

AI summary

A method of manufacturing a display device includes disposing a polarizing layer on one surface of a display panel including a thin film transistor and a pixel electrode, cutting the polarizing layer using a first laser beam so that a step between a side surface of the polarizing layer and a side surface of the display panel is smaller than a predetermined value, attaching a conductive film to the side surface of the display panel, and patterning the conductive film using a second laser beam.