Alignment Line Bridge Structure for Corrosion-Resistant Displays
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Solution Overview
Problem
Display devices face challenges in preventing corrosion of alignment lines, particularly when undercut metal patterns occur at the edge of the display panel, which can lead to structural integrity issues and performance degradation.
Innovation Solution
Incorporating a bridge portion that electrically connects metal patterns through a contact structure with a bridge contact hole, allowing for the prevention of corrosion even if undercut occurs, and using a laser etching process to ensure precise alignment and separation of metal patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal patterns are used for alignment lines in the first metal layer, then electrical connection and structural support are provided, but corrosion occurs at the edge of the substrate leading to structural integrity issues
Solution Approach 1:
A bridge portion is introduced as an intermediary element disposed in the third metal layer to electrically connect metal patterns that are spaced apart in the first metal layer. This bridge portion acts as a mediator that maintains electrical continuity and structural integrity without requiring continuous metal patterns that are susceptible to corrosion at edges. The bridge portion is formed after the light emitting elements are aligned, ensuring functionality while preventing corrosion-related failures.
2Reliability
If metal patterns are spaced apart in the first metal layer for alignment line function, then electrical connection is maintained, but structural integrity is compromised due to gaps and potential corrosion
Solution Approach 1:
The solution transitions from a two-dimensional continuous metal pattern to a three-dimensional structure by introducing a bridge portion in the third metal layer that vertically connects spaced-apart metal patterns in the first metal layer. This dimensional transition allows the metal patterns to be spaced apart horizontally while maintaining both electrical connection and structural integrity through the vertical bridge structure.
3Manufacturing precision
If laser etching is used to separate metal patterns precisely, then alignment precision is improved, but manufacturing complexity increases
Solution Approach 1:
The bridge portion is formed in the third metal layer before the final separation of the display panel. By preliminarily establishing the electrical connection through the bridge portion while the metal patterns are still connected to the substrate, the subsequent separation process becomes simpler and more precise. The preliminary formation of the bridge structure enables accurate alignment without requiring complex real-time etching control during the separation process.
Data Source
AI summary
A display device comprises a thin film transistor layer comprising a first metal layer disposed on a substrate and a thin film transistor disposed on the first metal layer, first and second electrodes disposed in a display area on the thin film transistor layer and extending in parallel in a direction, a plurality of light emitting elements disposed between the first and second electrodes, and an alignment line disposed in a non-display area disposed adjacent to the display area and electrically connected to the first and second electrodes. The alignment line comprises metal patterns disposed in the first metal layer and spaced apart from each other, and a bridge portion disposed on the first metal layer and electrically connected to the metal patterns.