Array Substrate Reflective Layers for Laser Etching Protection
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Solution Overview
Problem
The manufacturing of ultra-large-sized micro LED display devices is hindered by technical challenges such as the massive transfer and repair of dead pixels, making it difficult to produce large-sized products directly, and current solutions involve tiling small-sized display screens.
Innovation Solution
The use of an array substrate with a substrate, a trace layer, and protective layers, including reflective and energy-absorbing layers, to prevent laser light damage during etching processes, ensuring the integrity of connection traces and active layers, thereby improving product yield and image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser light is used for etching the trace layer and second electrodes, then manufacturing efficiency is improved, but the substrate and underlying layers are damaged by laser light penetration
Solution Approach 1:
The patent introduces a protective layer as an intermediary between the substrate/trace layer and the laser light source. This protective layer specifically absorbs laser light energy while being transparent to visible light, thereby protecting the underlying layers from laser damage during etching processes without affecting the display function.
Solution Approach 2:
The patent converts the harmful laser light energy into a beneficial protective function by using materials with specific optical properties. The protective layer absorbs the harmful laser wavelengths while maintaining transparency to visible light, effectively transforming the harmful laser exposure into a controlled protective mechanism.
2Reliability
If multiple protective layers are added to prevent laser damage, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent applies protective layers selectively at specific locations where laser light penetration causes damage, rather than uniformly across the entire device. The protective layers are positioned between the substrate and trace layer, and between the substrate and second electrodes, providing targeted protection only where needed.
Solution Approach 2:
The protective structure is divided into multiple segmented protective layers positioned at different locations within the device stack. Each protective layer serves a specific protective function at its location, allowing the system to address laser damage issues at multiple critical interfaces without requiring a single complex protective structure.
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 enhances the reliability and efficiency of large-sized display panel production by preventing laser light-induced damage, ensuring accurate brightness control and reducing color deviations, thus stabilizing image quality and increasing production yield.
Implementation Method 1
at least one protective layer includes a reflective layer
Implementation Method 2
at least one protective layer includes an energy absorbing layer
Data Source
AI summary
An array substrate includes: a substrate, a trace layer, a plurality of second electrodes and one or more protective layers. The trace layer is provided on the substrate. The plurality of second electrodes are provided on a side of the substrate away from the trace layer, and the trace layer is electrically connected to the plurality of second electrodes. A protective layer is provided between the substrate and the trace layer, and/or another protective layer is provided between the substrate and the plurality of second electrodes.