Tiled Display Interconnect Structure for Low-Seam Large Screens
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Solution Overview
Problem
Large display devices face increased defect rates and reduced productivity due to the number of pixels, and tiled display devices have visible seams that disrupt immersion, especially when displaying a single image across multiple units.
Innovation Solution
A display device design that includes a display layer with thin-film transistors, connection lines, barrier layers, lead lines, and a lower film made of organic materials, eliminating the need for a separate polyimide substrate and allowing for a seamless connection between adjacent display units by using a printing or coating process to form the lower film, which reduces defects and step differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a large size display device is manufactured, then the screen size is increased, but the defect rate of light emitting elements increases and productivity is reduced
Solution Approach 1:
The display device is divided into multiple small display modules that are tiled together to form a large display. Each module contains its own light emitting elements and is manufactured separately, allowing for better quality control and reduced defect rates in individual modules while achieving a large overall display area.
Solution Approach 2:
Multiple small display modules are nested or tiled together to form a larger display structure. The modules are arranged in a grid pattern with connection regions between them, enabling the construction of a large display device from smaller, more reliable modular units.
2Area of stationary object
If a tiled display device is implemented, then the large screen is provided, but the boundary part between display devices creates a sense of separation and reduces image immersion
Solution Approach 1:
The connection region between adjacent display modules is filled with a light emitting element that emits light in the same color as the surrounding display area. This color matching makes the boundary between modules invisible, creating a seamless visual experience and eliminating the sense of separation.
Solution Approach 2:
The connection region is integrated with the display area by using the same light emitting technology and color characteristics. This merging of the connection region with the display region makes the boundary imperceptible, allowing the tiled display to function as a unified large screen.
3Strength
If a separate polyimide substrate is used, then the display layer is supported, but the processing freedom is reduced and defect rate increases
Solution Approach 1:
The separate polyimide substrate is removed from the structure. Instead, the lower film itself provides the necessary support function, eliminating the need for an additional substrate layer and thereby increasing processing freedom and reducing manufacturing complexity.
Solution Approach 2:
The lower film is designed to perform multiple functions simultaneously: it provides mechanical support for the display layer, acts as a barrier layer, and serves as the base structure for the entire display module. This multi-functionality eliminates the need for a separate polyimide substrate.
4Productivity
If conventional manufacturing processes are used, then the display device is produced, but step differences and defects occur at the connection regions
Solution Approach 1:
The lower film is formed using a coating process with controlled parameters (viscosity, coating speed, drying conditions) to ensure uniform thickness and eliminate step differences at the connection regions. This precise parameter control achieves both high productivity and manufacturing precision.
Solution Approach 2:
The mechanical assembly process that caused step differences is replaced by a coating process where the lower film is deposited in a single continuous operation. This substitution of the manufacturing method eliminates the mechanical alignment and bonding steps that previously created precision problems.
Data Source
AI summary
A display device includes a display layer comprising pixels, each of the pixels having at least one thin-film transistor, a connection line electrically connected to the at least one thin-film transistor, the connection line being exposed on a lower surface of the display layer through a first contact hole formed in the display layer, a barrier layer disposed on the lower surface of the display layer and including a second contact hole connected to the first contact hole, a lead line disposed on a lower surface of the barrier layer and electrically connected to the connection line through the second contact hole, a pad part disposed on the lower surface of the barrier layer and electrically connected to the lead line, and a lower film overlapping the lower surface of the barrier layer and the lead line.