Display Panel Contact Stack Layout for Cut-Edge Integrity
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Solution Overview
Problem
The periphery circuit region of display panels is prone to damage during the cutting process, leading to defects that affect the imaging performance and splicing accuracy of display devices.
Innovation Solution
A display panel design featuring a contact stack with a recessed interlayer insulation layer between metal layers, which minimizes damage during cutting by maintaining the integrity of the interlayer insulation layer and preventing crack or breakage, ensuring the contact stack remains intact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the interlayer insulation layer extends to the substrate sidewall, then the electrical connection is improved, but the periphery region is damaged during cutting
Solution Approach 1:
The interlayer insulation layer is segmented into different regions: a first region that extends to the substrate sidewall to ensure electrical connection, and a second region that is recessed from the substrate sidewall to prevent damage during cutting. This spatial segmentation allows the same layer to fulfill both conflicting requirements in different areas.
Solution Approach 2:
Different portions of the interlayer insulation layer have different spatial extensions relative to the substrate sidewall. The first portion (first region) has maximum extension for electrical connection, while the second portion (second region) has reduced extension for cutting protection. This local variation in quality resolves the contradiction between electrical performance and mechanical durability.
2Illumination intensity
If multiple display panels are spliced to form display area, then the image quality and maintenance are improved, but the periphery region damage affects splicing accuracy
Solution Approach 1:
The display device is divided into multiple independent display panels that can be manufactured separately and then spliced together. The protected periphery region of each panel ensures that the cutting edges remain intact, enabling precise alignment and splicing of multiple panels to achieve high image quality without compromising splicing accuracy.
3Object-affected harmful factors
If the interlayer insulation layer is recessed from substrate sidewall, then the cutting damage is prevented, but the electrical connection may be affected
Solution Approach 1:
The interlayer insulation layer is divided into functional zones: a first region extending to the substrate sidewall that maintains electrical connection integrity, and a second region recessed from the sidewall that protects against cutting damage. This segmentation allows simultaneous achievement of both protection and connectivity.
Solution Approach 2:
The solution transitions from a single-dimensional extension (either full or recessed) to a two-dimensional spatial configuration where the interlayer insulation layer has different extensions in different lateral positions. This dimensional approach allows the layer to optimize for electrical connection in one area while optimizing for mechanical protection in another area.
Data Source
AI summary
The present disclosure provides a display panel including a substrate, a pixel pad layer above the substrate, and a contact stack above the substrate and electrically connected the pixel pad layer. The contact stack includes a first metal layer, a second metal layer above the first metal layer, and a first interlayer insulation layer between the first metal layer and the second metal layer. The first interlayer insulation layer includes a first top portion covering an edge of a top surface of the first metal layer. The second metal layer is electrically connected to the top surface of the first metal layer exposed by the first interlayer insulation layer. A sidewall of the first interlayer insulation layer is recessed from a sidewall of the substrate by a first distance greater than zero.