Bridge-Structured Display Panel Leads for Etch-Free Tiled Assembly
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Solution Overview
Problem
The manufacturing of Micro LED and Mini LED display devices faces challenges in reducing manufacturing costs and avoiding damage to front film layers and devices due to etching processes, while also ensuring high precision and reliability of connecting leads, particularly in the assembly of large-size display devices from small-size display devices.
Innovation Solution
The use of a bridge structure on the substrate's second surface to support back electrodes, combined with a controlled spacing and angle configuration of the bridge structure's surfaces, allows for precise placement of back electrodes and connecting leads, reducing manufacturing costs and improving the reliability and uniformity of connecting leads through a printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If etching processes are used to create connecting leads, then precise placement can be achieved, but front film layers and devices may be damaged
Solution Approach 1:
The patent introduces a bridge structure as an intermediary element that carries the connecting leads away from the front film layers. The bridge structure includes a first surface, second surface, and side surfaces that provide a platform for placing connecting leads without requiring etching of the front film layers, thus avoiding damage while maintaining precise placement capability
Solution Approach 2:
The patent moves the connecting leads from the two-dimensional plane of the front film layers to a three-dimensional bridge structure. By utilizing the vertical dimension and creating a separate bridge structure with controlled spacing and angles, the connecting leads are positioned in a different spatial dimension, eliminating the need for harmful etching processes on the front film layers
2Reliability
If traditional assembly methods are used for large-size display devices, then manufacturing may be simpler, but precision and reliability of connecting leads deteriorate
Solution Approach 1:
The patent performs preliminary actions by pre-configuring the bridge structure with specific spacing and angle parameters before assembling the connecting leads. The bridge structure is designed in advance with optimized dimensions (first spacing, second spacing, third spacing) and angles to ensure precise placement and high reliability of connecting leads, reducing the need for complex adjustments during final assembly
Solution Approach 2:
The patent systematically changes and optimizes multiple geometric parameters of the bridge structure, including first spacing (between first and second surfaces), second spacing (orthographic projection spacing), third spacing (distance from second common edge to first side surface), and various angles. These parameter changes enable precise control over connecting lead positioning, improving reliability while managing assembly complexity through standardized design
3Manufacturing precision
If the bridge structure surfaces are not precisely configured, then manufacturing is easier, but precision of back electrode placement deteriorates
Solution Approach 1:
The patent segments the bridge structure into distinct surfaces (first surface, second surface, side surfaces) with clearly defined spacing and angular relationships. This segmentation allows each surface to be manufactured and measured independently, facilitating precise back electrode placement while maintaining manufacturing feasibility through modular construction approaches
Data Source
AI summary
A display panel includes a substrate, a bridge structure, back electrodes, and connecting leads. The substrate includes first and second surfaces, and at least one selected first side surface. The bridge structure includes third and fourth surfaces, and at least one selected second side surface. The third and fourth surfaces have a first spacing. Each connecting lead includes first, second and third portions respectively on sides of the first surface, the selected first side surface, and the second surface. The third part includes portions respectively on the second surface, the selected second side surface, and a side of the fourth surface. On the third surface, an orthographic projection of a first common edge between the selected second side surface and the fourth surface and an orthographic projection of a second common edge between the selected second side surface and the third surface have a second spacing.