LED Display Base Plate Layout for Short-Circuit and Over-Etch Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing LED displaying base plates suffer from short-circuit and open-circuit imperfections due to inadequate coverage by passivation layers and over-etching during the etching process, leading to voltage drop issues and imperfect grayscale control.
Innovation Solution
A displaying base plate structure comprising a substrate with a first and second flat layer, and a first and second metal layer, where the second flat layer covers the first metal trace and the second metal layer, and a passivation layer is used to enhance adhesivity and prevent corrosion, with a bonding block to protect the substrate from over-etching, ensuring effective coverage and preventing short and open circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If passivation layer coverage is reduced to simplify manufacturing, then manufacturing complexity decreases, but short-circuit imperfections occur between metal layers
Solution Approach 1:
The patent introduces a flat layer as an intermediary component between the first metal layer and second metal layer. This flat layer completely covers the metal traces and provides a stable base for the passivation layer, preventing direct contact between overlapping metal layers while simplifying the overall manufacturing process by establishing a clear hierarchical structure
Solution Approach 2:
The patent adds a vertical dimension to the structure by introducing flat layers that completely cover the metal traces. This vertical coverage creates physical separation between metal layers in the Z-direction, preventing short-circuits while allowing overlapping in the XY-plane for compact design
2Manufacturing precision
If etching process is intensified to improve pattern definition, then manufacturing precision improves, but over-etching occurs damaging the substrate
Solution Approach 1:
The patent introduces a bonding block as a protective structure before the etching process. This bonding block serves as a cushioning element that absorbs or prevents over-etching from reaching and damaging the substrate, allowing the etching process to be performed with sufficient intensity to achieve good pattern definition without risking substrate damage
3Area of stationary object
If metal layers are placed closer together to reduce device size, then area decreases, but short-circuit risk increases due to inadequate passivation coverage
Solution Approach 1:
The patent resolves the conflict between compact area and short-circuit prevention by utilizing the vertical dimension. The flat layer completely covers the metal traces in the XY-plane while extending vertically to provide separation, allowing metal layers to be positioned close together horizontally while maintaining adequate insulation through the vertical coverage of the flat layer
Data Source
AI summary
A displaying base plate and a fabricating method thereof. The displaying base plate includes a substrate, and a first flat layer on one side of the substrate; a first metal layer on one side of the first flat layer that is further away from the substrate; a second flat layer on sides of the first metal layer and the first flat layer that are further away from the substrate; and a second metal layer on one side of the second flat layer that is further away from the substrate; wherein the first metal layer includes a first metal trace, an orthographic projection of the second metal layer on the substrate and an orthographic projection of the first metal trace on the substrate have an overlapping part, and an orthographic projection of the second flat layer on the substrate covers the orthographic projection of the first metal trace on the substrate.