Barrier-Layer Pad Structure for Seamless Tiled Displays

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Large-sized display devices face increased defect rates and productivity issues due to the number of pixels, leading to reliability concerns and a sense of disconnection when tiled, as boundary portions between connected displays are noticeable, reducing immersion.

Innovation Solution

A display device design featuring a barrier layer with amorphous carbon, pad parts, and insulating layers to prevent damage, particle generation, and film lifting during manufacturing, while minimizing non-display areas by electrically connecting pad parts to flexible films, thereby reducing the visibility of boundaries between tiled displays.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If contact holes are formed to penetrate the substrate to expose the pad part, then electrical connection is achieved, but the pad part may be damaged or particles may be generated on its bottom surface

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidpad part damage and particle generation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A barrier layer comprising amorphous carbon is introduced as an intermediary between the substrate and the pad part. This barrier layer protects the pad part from damage and prevents particle generation during contact hole formation while still allowing electrical connection to be established through the contact holes that penetrate both the substrate and the barrier layer to expose the pad part

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the pad part is directly disposed on the substrate, then manufacturing is simplified, but film lifting phenomenon occurs during contact hole formation

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidfilm lifting phenomenon

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The barrier layer comprising amorphous carbon serves as a mediator between the substrate and the pad part, preventing direct contact that leads to film lifting. The barrier layer's presence stabilizes the pad part position during contact hole formation while adding minimal complexity to the manufacturing process

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If non-display areas are minimized in tiled display devices, then sense of immersion is improved, but boundary portions become more visible

Engineering Contradiction:

Improvesense of immersionVSAvoidboundary visibility

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The barrier layer is selectively removed or opened in contact hole regions to expose the pad part, while maintaining its presence in other areas. This extraction approach allows electrical connection through contact holes while the barrier layer continues to protect against particle generation and pad part damage in non-contact hole areas

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS12261191B2Display device having a pad part disposed on a barrier layer, method of manufacturing the same and tiled display device including the same

Publication Date: 2025.03.25 SAMSUNG DISPLAY CO LTD

AI summary

Provided is a display device. The display device comprises a first substrate, a barrier layer disposed on the first substrate and having amorphous carbon, a first pad part disposed on the barrier layer, a second substrate disposed on the first pad part, a display layer disposed on the second substrate, and a second pad part disposed on a bottom surface of the first substrate and inserted into a first contact hole formed in the first substrate and the barrier layer.