Display Edge Coating Layout for Accurate LED Transfer

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Solution Overview

Problem

Tiled display devices face issues with contact failures due to the coating pattern during the transfer of light emitting elements to the substrate, which exposes side surface lines to moisture and oxygen, making them visible to users.

Innovation Solution

A method of manufacturing a display device involves forming a thin film transistor layer on a substrate, applying first and second coating patterns to cover side surface lines, and transferring light emitting elements using a stamp method with an elastic polymer material, ensuring consistent heights and chamfer surfaces to prevent contact failures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a coating pattern is applied to cover the side surface line, then the side surface line is protected from moisture and oxygen and prevented from being visible, but contact failures occur during the transfer of light emitting elements to the substrate

Engineering Contradiction:

Improveprotection of side surface lineVSAvoidcontact accuracy during transfer

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The coating pattern is divided into two distinct parts: a first coating pattern applied to the front surface and a second coating pattern applied to the rear surface. This segmentation allows each coating pattern to be optimized independently - the first coating pattern can be made thinner to prevent contact failures during transfer, while the second coating pattern provides the necessary protection and coverage on the rear surface, thus resolving the contradiction between protection and manufacturing precision.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If the coating pattern thickness is reduced to prevent contact failures, then contact accuracy during transfer is improved, but the protective coverage of the side surface line is compromised

Engineering Contradiction:

Improvecontact accuracy during transferVSAvoidprotection of side surface line

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The solution transitions from a single-dimensional coating (one layer on the front surface) to a two-dimensional coating system (first coating pattern on the front surface and second coating pattern on the rear surface). This dimensional change allows the front surface coating to be thin for accurate transfer, while the rear surface coating provides the necessary protective coverage, thus resolving the contradiction between manufacturing precision and reliability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If multiple coating patterns are applied to ensure complete coverage, then protection and visibility prevention are improved, but device complexity increases

Engineering Contradiction:

Improveprotection and visibility preventionVSAvoidcoating pattern structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Different coating patterns are applied to different locations of the substrate: the first coating pattern is applied to the front surface where light emitting elements are transferred, and the second coating pattern is applied to the rear surface for protection. Each location receives a coating pattern with properties optimized for its specific function, allowing complete coverage and protection without requiring a uniformly complex structure throughout the entire device.

Inventive Principle:

Principle #3Local quality

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

The method prevents contact failures during the transfer of light emitting elements by reducing the thickness of the coating pattern, enhancing the durability and visibility of tiled display devices.

Implementation Method 1

transferring light emitting elements to the thin film transistor layer... transferring light emitting elements using a stamp method with an elastic polymer material

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

The metal layer may be integrally formed in the edge area by a sputtering process

Methodology Applied

Scientific EffectSputtering: Sputtering

Data Source

PatentUS12525592B2Display device and method of manufacturing the same

Publication Date: 2026.01.13 SAMSUNG DISPLAY CO LTD

AI summary

A method of manufacturing a display device includes forming a thin film transistor layer in an active area of a substrate, forming a metal layer on an edge area of the substrate, transferring first coating patterns to the edge area, the first coating patterns covering a portion of the metal layer corresponding to shapes of side surface lines, etching the metal layer to form the side surface lines, an upper surface of each of the side surface lines being covered by the first coating patterns, transferring a second coating pattern to the edge area, the second coating pattern covering a side surface of each of the side surface lines and the first coating patterns, and transferring light emitting elements to the thin film transistor layer. The second coating pattern includes openings corresponding to the first coating patterns in a plan view.