Stretched Display Panel Cutting Method for Noise Reduction
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Solution Overview
Problem
Conventional display panel cutting methods result in high defect rates due to noise generation from conductive foreign matter, leading to the discarding of non-standardized panels, which cannot be restored.
Innovation Solution
A method of cutting a display panel to form a pixel exposure portion on the TFT substrate, with a short-circuit prevention seal and cutoff line to prevent short circuits, and a reinforcement seal to increase rigidity, minimizing noise and enabling restoration of defective panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the conventional cutting method is used where both substrates are cut to the same length, then the cutting process is simple, but conductive foreign matter separates from circuits and causes noise due to short circuits
Solution Approach 1:
The invention divides the cutting process into two distinct stages: first cutting the TFT substrate to expose pixel lines, then cutting the color filter substrate separately. This segmentation prevents conductive foreign matter from causing short circuits by ensuring the TFT substrate is already cut and isolated before the color filter substrate is cut, eliminating the noise problem while maintaining manufacturing feasibility
Solution Approach 2:
The TFT substrate is cut in advance before cutting the color filter substrate. This preliminary action exposes the pixel lines and isolates the TFT substrate circuits, preventing conductive foreign matter from bridging circuits during the subsequent color filter substrate cutting process, thereby preventing short circuit noise
2Adaptability or versatility
If standardized display panels are cut to non-standardized sizes, then non-standardized display panels can be obtained, but the defect rate is high due to noise from conductive foreign matter
Solution Approach 1:
The cutting process is segmented into two independent operations: cutting the TFT substrate first to custom dimensions, then cutting the color filter substrate to match or slightly smaller dimensions. This segmentation enables flexible custom size production while preventing the high defect rate caused by conductive foreign matter, as the TFT substrate is already isolated before the second cutting operation
Solution Approach 2:
The TFT substrate is cut to the desired custom size in advance, exposing the pixel lines and isolating the circuits. This preliminary cutting action enables subsequent customization of the color filter substrate without risking short circuits from conductive foreign matter, thereby reducing defects while achieving adaptability for various custom sizes
3Reliability
If display panels with noise are discarded, then defective panels are removed, but resource waste and financial loss increase
Solution Approach 1:
The invention applies preliminary protective measures during the cutting process itself - cutting the TFT substrate first to expose and isolate pixel lines, then applying sealant to prevent conductive foreign matter from causing short circuits. This preliminary anti-action prevents noise generation at the source, eliminating the need to discard panels and preventing resource waste and financial loss
Data Source
AI summary
A method of manufacturing a stretched display panel, includes: cutting the TFT substrate to a desired size; cutting the color filter substrate so as to have a length smaller than a length of the TFT substrate such that a pixel exposure portion, from which one or more horizontal pixel lines are exposed, is formed at the TFT substrate; forming a short-circuit prevention seal for covering one of the horizontal pixel lines that is adjacent to an end of the color filter substrate in order to prevent occurrence of a short circuit due to introduction of foreign matter; and forming an cutoff line for cutting off the horizontal pixel line(s) that is not covered by the short-circuit prevention seal and the horizontal pixel line that is covered by the short-circuit prevention seal from each other.