Display Device Protective Layer Step-Difference Pattern
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Solution Overview
Problem
Display devices face contact failure issues between substrates due to height differences and structural complexities in non-display areas, which affect the reliability and efficiency of electrical connections.
Innovation Solution
A display device design featuring a step-difference pattern on the gate pad with a protective layer structure, including a first protective layer and a second protective layer with a contact hole, and a transparent electrode connected through a conductive ball, along with a light shielding portion and column spacer, to reduce contact failure and enhance connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional protective layer structure is used without step-difference patterns, then the manufacturing process is simpler, but contact failure between substrates increases due to height differences in the non-display area
Solution Approach 1:
The protective layer is segmented into a first protective layer and a second protective layer with different heights. The second protective layer has a reduced height in the non-display area to minimize step differences and improve contact reliability between substrates, while the first protective layer maintains full height in the display area for adequate protection.
Solution Approach 2:
Different regions of the protective layer are given different heights to satisfy local requirements. The display area requires full protective layer height for reliability, while the non-display area benefits from reduced height to minimize contact issues. This local differentiation resolves the contradiction between contact reliability and structural complexity.
2Reliability
If a step-difference pattern is introduced on the gate pad, then contact failure between substrates is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The protective layer is formed as two separate layers with different heights, creating a step-difference pattern on the gate pad in the non-display area. This segmentation reduces contact failure between substrates while the manufacturing process uses standard photolithography and etching techniques to achieve the required height precision without excessive complexity.
Data Source
AI summary
A display device includes: a first substrate including a display area and a non-display area; a gate line in the display area and a gate pad in the non-display area, the gate line extending in a first direction; a data line in the display area, the data line extending in a second direction intersecting the first direction; a thin film transistor at an intersection point among the gate line and the data line; a step-difference pattern on the gate pad; and a protective layer including a first protective layer on the thin film transistor and a second protective layer on the step-difference pattern and the gate pad. The second protective layer has a height less than a height of the first protective layer.