Display Base Layer Blocking Structure for Laser Pad Exposure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current display device manufacturing processes face inefficiencies and are prone to short-circuit defects, particularly in the integration of light emitting elements and electrical connections.
Innovation Solution
The proposed solution involves a display device structure with a base layer comprising multiple layers, including blocking layers of different materials and thicknesses, and a manufacturing method that uses a laser process to expose pads while preventing laser transmission to critical areas, thereby enhancing process efficiency and preventing short-circuit defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If blocking layers are disposed between the first base layer and the second base layer to prevent short-circuit defects, then reliability is improved, but device complexity increases due to additional layers and materials
Solution Approach 1:
The blocking layers are divided into multiple separate layers (first blocking layer and second blocking layer) disposed at different heights, rather than using a single thick blocking layer. This segmentation allows each layer to perform specific functions and reduces overall complexity while maintaining reliability.
Solution Approach 2:
The blocking layers are arranged in different vertical layers (different z-dimensions) rather than horizontally adjacent. The first blocking layer is disposed between the first base layer and second base layer, while the second blocking layer is disposed between adjacent pads, creating a three-dimensional spatial arrangement that prevents short-circuits more effectively.
2Productivity
If a laser process is used to expose pads during manufacturing, then productivity is improved, but harmful factors increase due to potential laser transmission to critical areas
Solution Approach 1:
The blocking layers are disposed in advance (before the laser exposure process) to prevent harmful laser transmission. The first blocking layer and second blocking layer are strategically positioned to block laser paths to critical areas such as light emitting elements, preventing damage before it can occur during the laser exposure process.
Solution Approach 2:
The blocking layers act as intermediary elements between the laser exposure process and the critical components (light emitting elements, pads). These intermediate layers absorb or block the laser energy, protecting the underlying components while allowing the laser process to proceed for pad exposure.
3Reliability
If multiple blocking layers with different materials and thicknesses are used to ensure reliable electrical connections, then reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
Different blocking layers are made from different materials with different thicknesses according to their specific functional requirements. The first blocking layer and second blocking layer have locally optimized properties - each layer's material composition and thickness are tailored to its specific position and function, rather than using uniform properties throughout.
Solution Approach 2:
The blocking structure uses composite material composition with at least two different materials for the first and second blocking layers. This allows each layer to be optimized for its specific function - for example, one layer may use a material optimized for laser blocking while another uses a material optimized for electrical isolation - reducing the overall manufacturing precision requirements.
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 manufacturing efficiency of display devices by reducing the risk of short-circuit defects and ensuring reliable electrical connections between light emitting elements and pads.
Implementation Method 1
a manufacturing method that uses a laser process to expose pads while preventing laser transmission to critical areas
Data Source
AI summary
A display device includes a base layer including a first base layer and a second base layer disposed on a rear surface of the first base layer, light emitting elements disposed on a surface of the first base layer, and pads including a first pad and a second pad, which are disposed on the rear surface of the first base layer and are spaced apart from each other. The base layer further includes blocking layers which are disposed between the first base layer and the second base layer and at least portions of the blocking layers do not overlap the pads in a plan view. The blocking layers include a first blocking layer and a second blocking layer, which are disposed in different layers.