Flat Panel Display Alignment Pads with Resistor for Probe Verification

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Solution Overview

Problem

Flat panel displays, such as LCDs and OLEDs, face challenges in detecting misalignment between inspection probes and pads during the manufacturing process, leading to defects and increased inspection time.

Innovation Solution

A flat panel display design that includes specific pads for receiving driving, inspection, and alignment confirmation signals, with a resistor between alignment confirmation pads to accurately determine probe alignment using resistance values, ensuring precise alignment before inspection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional inspection methods are used without alignment confirmation pads, then the inspection process is simpler, but misalignment between probes and inspection pads occurs leading to defects

Engineering Contradiction:

Improveinspection accuracyVSAvoidpad structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The pad structure is segmented into three distinct types: driving pads (first pads), inspection pads (second pads), and alignment confirmation pads (third pads). This segmentation allows each pad type to serve its specific function independently, with the alignment confirmation pads providing dedicated alignment verification without interfering with driving or inspection operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The alignment confirmation pads act as an intermediary element between the driving pads and inspection pads. By providing a separate alignment verification mechanism, they mediate the alignment process to ensure accurate probe positioning before actual inspection occurs, preventing misalignment-related defects.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If alignment confirmation pads with resistors are added, then probe alignment accuracy improves, but manufacturing complexity increases

Engineering Contradiction:

Improvealignment measurement precisionVSAvoidmanufacturing ease

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The alignment confirmation pads incorporate resistors with specific resistance values to enable electrical measurement of alignment status. By changing the electrical parameters (resistance values) of the pads, the system can detect whether probes are correctly aligned through resistance measurements, providing precise alignment verification.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces mechanical alignment verification methods with electrical measurement methods. Instead of using mechanical fixtures or visual alignment tools, the system uses electrical resistance measurements through the pads and resistors to detect probe alignment status, enabling more precise and automated alignment verification.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If multiple types of pads are used for different functions, then inspection accuracy and alignment confirmation improve, but inspection time increases

Engineering Contradiction:

Improvepad alignment precisionVSAvoidinspection time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The alignment confirmation pads enable preliminary alignment verification before the actual inspection process begins. By confirming probe alignment with the inspection pads through the third pads in advance, the system prevents misalignment defects and avoids re-inspection, ultimately reducing total inspection time despite the additional alignment step.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system provides feedback on probe alignment status through the resistance measurements taken at the alignment confirmation pads. This feedback mechanism allows real-time verification of alignment, enabling operators to adjust probe positions immediately if misalignment is detected, ensuring accurate inspection without unnecessary time loss from undetected misalignment.

Inventive Principle:

Principle #23Feedback

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 effectively reduces the defect rate by ensuring accurate alignment between inspection probes and pads, thereby enhancing inspection efficiency and accuracy.

Implementation Method 1

a resistance value of the resistor is larger than a resistance value of the probes of the inspection apparatus

Methodology Applied

Scientific EffectElectrical Resistance: Electrical Resistance

Data Source

PatentUS11264442B2Flat panel display including plurality of pads

Publication Date: 2022.03.01 SAMSUNG DISPLAY CO LTD

AI summary

A flat panel display includes a substrate including a display region and a non-display region disposed outside of the display region, a display unit disposed in the display region that displays an image, a plurality of first pads disposed in the non-display region that receive driving signals for driving the display unit, a plurality of second pads disposed in the non-display region that receive inspection signals for inspecting the display unit, a plurality of third pads disposed in the non-display region that receive alignment confirmation signals for confirming alignment, and a resistor coupled between at least two third pads of the plurality of third pads.