Array Substrate Data Line Self-Repair via Gate Layer Contact
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Solution Overview
Problem
Liquid crystal display devices often suffer from broken data lines during manufacturing, leading to uneven color and low product yield due to the lack of self-repair functionality in existing technologies.
Innovation Solution
The introduction of an array substrate with a data line self-repairing function, where a translucent area is created between pixel units, allowing the data layer to contact the gate layer, enabling conductive connection and automatic self-repair of disconnected data lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the data layer is completely covered by insulating layers during manufacturing, then the manufacturing process is simplified, but broken data lines cannot be self-repaired resulting in low product yield
Solution Approach 1:
The gate insulating layer is selectively removed only at opening areas where data lines may break, while remaining intact in other areas. This local modification allows the data layer to contact the gate layer for self-repair without affecting the overall manufacturing process or other functional areas.
Solution Approach 2:
Opening areas are pre-defined in the gate insulating layer during the manufacturing process, creating advance pathways for potential data line self-repair. This preliminary preparation ensures that when breaks occur, the repair mechanism is already in place without requiring additional manufacturing steps.
2Reliability
If opening areas are created in the gate insulating layer to enable data line self-repair, then broken data lines can be automatically repaired, but the manufacturing process becomes more complex
Solution Approach 1:
The opening areas in the gate insulating layer are integrated with the existing transistor gate structure and data line layout. The same opening areas serve dual purposes: defining the gate region and providing self-repair pathways, thereby combining multiple functions without adding separate manufacturing steps.
Solution Approach 2:
The gate insulating layer openings serve multiple functions: they define the gate electrode region, provide electrical connection pathways for self-repair, and maintain the transistor's electrical characteristics. This multi-functionality reduces the need for additional specialized structures.
3Reliability
If the gate insulating layer covers the gate layer completely, then electrical insulation is maintained, but disconnected data lines cannot connect to the gate layer for repair
Solution Approach 1:
The gate insulating layer is selectively removed only at specific opening areas where data line connections are needed, while maintaining full coverage and insulation in all other areas. This localized approach preserves electrical insulation wherever required while enabling connectivity where repair is needed.
Solution Approach 2:
The opening areas in the gate insulating layer act as intermediary pathways that allow electrical connection between the data layer and gate layer without compromising the insulating function of the gate insulating layer in other regions. These openings serve as controlled conduits for electrical connectivity.
4Productivity
If data lines are made robust to prevent breaks, then manufacturing yield improves, but the device complexity increases
Solution Approach 1:
The data lines are equipped with self-service capability through the opening areas that enable automatic self-repair when breaks occur. The data layer directly contacts the gate layer through these openings, allowing the system to self-correct without external intervention or complex additional structures.
Solution Approach 2:
Instead of trying to completely prevent data line breaks through more complex robust structures, the invention converts the potential harm of breaks into a beneficial self-repair mechanism. The opening areas, which could be seen as structural modifications, actually enable the system to tolerate and automatically repair breaks.
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 solution reduces the unqualified rate of data lines during manufacturing and enhances the transmittance of liquid crystal display devices by allowing broken data lines to be automatically repaired, improving overall product quality.
Implementation Method 1
the data layer relative to the opening area contacts with the gate layer, so that a disconnected data line in the data layer connects conductively with the gate layer
Data Source
AI summary
An array substrate having a data line self-repairing function and a liquid crystal display device is disclosed. The array substrate comprises a plurality of pixel units, the pixel unit at least comprise a gate layer, a gate insulating layer, a data layer and a pixel electrode layer laminated therein. Every of the pixel unit have a translucent area and opening areas. The gate layer relative to the opening area is retained, and the gate insulating layer does not cover the gate layer, and the data layer relative to the opening area contacts with the gate layer so that a broken data line in the data layer has conductive connection through the gate layer. Through the above solution, the data line has automatic repair function for disconnection and the unqualified rate of the data line during the manufacture processes is reduced.