Chamfered Substrate Side Wiring for Bezel-less Displays

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Solution Overview

Problem

The challenge in the display device industry is to enhance the reliability of bezel-less display devices by effectively forming side wiring on the substrate surfaces while minimizing the bezel area, which is crucial for maximizing the display area without compromising the structural integrity and reducing the occurrence of chipping or cracks in the wiring.

Innovation Solution

A display device design featuring a substrate with chamfered surfaces and a manufacturing method that includes forming exposure openings in the insulating layer, depositing a side wiring material layer, and using laser irradiation to create side wiring, which connects pads on opposite surfaces of the substrate, ensuring electrical connectivity and reducing the risk of exhaust gas accumulation that could lead to reliability issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If side wiring is formed on the substrate surface to achieve bezel-less design, then the display area is maximized, but the reliability is reduced due to chipping or cracks in the wiring

Engineering Contradiction:
Improvedisplay areaVSAvoidwiring reliability
Core Design Contradiction:
Area of stationary objectVSReliability

Solution Approach 1:

The wiring structure transitions from a two-dimensional planar configuration to a three-dimensional structure that follows the chamfered surface geometry. The side wiring is formed to extend along the inclined chamfered surface rather than remaining flat on the substrate surface, distributing mechanical stress across multiple dimensions and reducing susceptibility to chipping and cracks while maintaining bezel-less display area.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The chamfered surface structure serves as a pre-designed stress distribution mechanism that cushions mechanical shocks and thermal stresses before they can cause damage to the wiring. The inclined surface geometry is formed in advance to redirect and dissipate forces that would otherwise concentrate at sharp edges and cause wiring failure.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

2Area of stationary object

If the bezel area is decreased to maximize display area, then the display area is increased, but the structural integrity is compromised

Engineering Contradiction:
Improvedisplay areaVSAvoidstructural integrity
Core Design Contradiction:
Area of stationary objectVSStrength

Solution Approach 1:

The substrate edge geometry is transformed from a simple flat surface to a multi-faceted chamfered structure with inclined surfaces. This dimensional change creates a more robust edge profile that maintains structural integrity while minimizing the visible bezel area, as the chamfered surfaces can be positioned to remain less visible or integrated into the display boundary.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The chamfered surface introduces asymmetric geometry to the substrate edge, creating a tapered profile that is stronger at the base and gradually reduces toward the display area. This asymmetric structure provides enhanced mechanical support where needed while allowing for minimal bezel visibility, resolving the conflict between structural strength and display area maximization.

Inventive Principle:
Principle #4Asymmetry

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 approach improves the reliability of the display device by ensuring robust side wiring connections, reducing the risk of chipping, and allowing for a bezel-less design that maximizes display area, thereby enhancing the overall performance and durability of the device.

Implementation Method 1

irradiating the side wiring material layer with a laser

Methodology Applied
Scientific EffectLaser heating: Laser

Data Source

PatentUS20230238495A1Display device and manufacturing method of manufacturing the same
Publication Date: 2023.07.27 SAMSUNG DISPLAY CO LTD
  • US20230238495A1 patent drawing
  • US20230238495A1 patent drawing
  • US20230238495A1 patent drawing

AI summary

A display device is provided, a display device includes, a substrate including a first surface, a second surface opposite to the first surface, a first chamfered surface extending from one side of the first surface, a second chamfered surface extending from one side of the second surface, and a first side surface connecting the first chamfered surface and the second chamfered surface to each other, a first pad on the first surface, an upper via layer on the first surface and spaced from the first pad, and a first passivation layer partially covering the upper via layer, and defining a first exposure opening exposing one side of the upper via layer facing the first pad.