Active Array Substrate Layout for Flexible Cutting Clearance
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Solution Overview
Problem
Current electrophoretic display devices require custom design for different sizes, leading to high manufacturing costs and a risk of short circuits during cutting, which reduces yield and reliability.
Innovation Solution
An active array substrate with defined cutting clearance regions allows for flexible sizing without additional masks, preventing conductor overlap and thus avoiding short circuits, enabling improved process flexibility and reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom design is used for different sized electrophoretic display devices, then device size adaptability is improved, but manufacturing cost increases
Solution Approach 1:
The substrate is divided into a display region and a non-display region, with the non-display region containing extended conductors that serve as cutting clearance regions. This segmentation allows the display region to be cut to different sizes while the extended conductors prevent short circuits at the cutting edges, enabling size adaptability without custom design for each size.
Solution Approach 2:
The extended conductors in the non-display region serve multiple functions: they act as electrical conductors for the display function and simultaneously serve as cutting clearance regions to prevent short circuits during cutting. This multi-functionality eliminates the need for additional mask processes and enables universal manufacturing across different device sizes.
2Adaptability or versatility
If cutting is performed on the display region, then device size flexibility is improved, but short circuit risk between conductors increases
Solution Approach 1:
The conductors are extended into the non-display region before cutting occurs. This preliminary extension creates a safety margin that ensures the cutting line will not sever or damage the conductors, thereby preventing short circuits while allowing flexible size adjustment of the display region.
Solution Approach 2:
The non-display region acts as an intermediary zone between the display region and the edge of the substrate. This intermediary region contains the extended conductors that are positioned away from the cutting line, serving as a buffer that prevents direct contact between cutting tools and conductors, thereby eliminating short circuit risk.
3Manufacturing precision
If additional mask is used for size modulation, then manufacturing precision is improved, but process complexity increases
Solution Approach 1:
The size modulation function is extracted from the display region and transferred to the non-display region through the extended conductors. By defining cutting lines based on these extended conductors rather than using masks on the display region, the need for additional mask processes is eliminated, reducing process complexity while maintaining size precision.
Data Source
AI summary
An active array substrate includes a substrate and a plurality of pixel structure disposed on the substrate. Each of the pixel structure includes a scan line, a data line, and a pixel electrode. The scan line is disposed on the substrate and extending along a first direction. The data line is disposed on the substrate and extending along a second direction. The first direction crosses the second direction. The data line and the scan line define a pixel region and a first cutting clearance region. The pixel electrode is disposed on the substrate and includes a first portion and a second portion. The first portion is on the pixel region. The second portion is on the first cutting clearance region. A normal projection of the second portion onto the substrate does not overlap a normal projection of the data line onto the substrate.