Stretched Display Panel Cutting Method for Noise Reduction
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Solution Overview
Problem
Conventional methods of cutting display panels result in high defect rates due to noise generation from conductive foreign matter, making it difficult to restore defective panels and leading to unnecessary discarding, with hermetic sealing also introducing foreign matter into gaps between substrates.
Innovation Solution
A method involving cutting the TFT substrate first, forming a pixel exposure portion on the color filter substrate, creating an open-circuit line to prevent electrical noise, and applying a reinforcement seal using an inclined nozzle to remove foreign matter, followed by a hermetically sealing seal to prevent foreign matter ingress, with optional carbon dioxide washing to remove micro-scale conductive foreign matter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the display panel is cut using conventional methods, then the panel can be resized to non-standardized dimensions, but conductive foreign matter separates from circuits and attaches to circuit substrates causing noise and short circuits
Solution Approach 1:
The patent applies preliminary protective actions before cutting: forming a protective film over circuits, pre-positioning spacers at cut locations, and preparing reinforcement seals in advance. These preliminary measures prevent foreign matter contamination and circuit damage before the cutting process begins, thereby maintaining reliability while enabling resizing.
Solution Approach 2:
The patent introduces intermediary elements to prevent direct contact between conductive circuits and foreign matter: protective films act as intermediaries between circuits and the environment, spacers serve as intermediaries between cutting tools and substrates, and reinforcement seals function as intermediaries between sealed spaces and external contaminants. These intermediaries eliminate the harmful interaction causing noise defects.
2Reliability
If the seal is applied using a spray nozzle in vertical or horizontal direction, then hermetic sealing can be achieved, but foreign matter flows into gaps between substrates or attaches to substrates causing noise defects
Solution Approach 1:
The patent applies asymmetric sealing strategies: the spray nozzle is positioned and oriented at specific asymmetric angles relative to the substrate gaps, creating a directional sealing flow that prevents foreign matter ingress while maintaining hermetic sealing. The asymmetric positioning ensures sealant is deposited away from gap regions where foreign matter could enter.
Solution Approach 2:
The patent applies local quality by varying sealing parameters in different regions: the spray nozzle operates with different angles, distances, and sealant flow rates for different portions of the seal region. Critical areas near substrate gaps receive enhanced protective sealing while other regions use standard sealing parameters, optimizing both hermetic sealing and foreign matter prevention locally.
3Reliability
If conductive foreign matter attaches to circuit substrates causing noise defects, then the display panel functionality is compromised, but restoration is difficult and panels must be discarded
Solution Approach 1:
The patent implements beforehand cushioning by forming protective films over circuits before cutting, positioning spacers to cushion against tool contact, and preparing reinforcement seals in advance. These cushioning measures create protective barriers that prevent foreign matter attachment in the first place, eliminating the need for restoration and avoiding panel discard.
Solution Approach 2:
The patent extracts potential sources of conductive foreign matter through preliminary filtering and removal processes before the cutting operation. By extracting contaminants from the processing environment and removing them before they can attach to circuits, the patent prevents noise defects and maintains panel functionality without requiring complex restoration procedures.
Data Source
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AI summary
The present invention relates to a stretched display panel fabricated by cutting an already-made display panel for displaying images, and a method for manufacturing the same. A method for manufacturing a stretched display panel according to an embodiment of the present invention is for the purpose of manufacturing a stretched display panel by cutting an already-made display panel comprising a color filter substrate and a TFT substrate into a desired size, and comprises the steps of: cutting the TFT substrate into a desired size; cutting the color filter substrate into a length smaller than that of the TFT substrate such that a pixel exposure portion is formed on the TFT substrate and exposes one or more horizontal pixel lines; forming a disconnection line on an end of the TFT substrate exposed by the pixel exposure portion so as to disconnect between a horizontal pixel line positioned on the end of the TFT substrate and an adjacent horizontal pixel line, thereby blocking inflow of electric noise through the horizontal pixel lines; and forming a reinforcement seal that reinforces rigidity of the pixel exposure portion concurrently with covering the pixel exposure portion by an encapsulation material so as to prevent a short circuit due to inflow of alien substances between the horizontal pixel lines. In the step of forming a reinforcement seal, a reinforcement material is applied while an application nozzle for applying the reinforcement material is arranged to slope from the end of the color filter substrate toward the end of the TFT substrate such that alien substances on the pixel exposure portion are pushed away and removed by the applied reinforcement material. Accordingly, the defect ratio can be minimized.