Display Insulating Layer Layout to Prevent Edge Chipping Defects
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Solution Overview
Problem
The manufacturing process of display apparatuses often results in foreign substances remaining in the display area, leading to defective light emission due to impurities created during the formation of various components.
Innovation Solution
A display apparatus design featuring a substrate with a wire extending along its edges, where a first insulating layer covers a portion of the substrate closer to the center than the wire, and a second insulating layer covers the first layer, with varying distances and curvature radii to minimize the occurrence of defects by preventing the chipping off of insulating layer parts during air spraying, thus reducing impurity-related defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating layers are formed during the manufacturing process, then electrical insulation is provided, but foreign substances may remain in the display area causing defective light emission
Solution Approach 1:
The patent extracts and removes foreign substances from the display area through a dedicated cleaning process using a nozzle that sprays cleaning solution and removes particles before the insulating layer formation, preventing contamination in the final product
Solution Approach 2:
The cleaning process is performed preliminarily before forming the insulating layers and wire structures, ensuring the display area is free from foreign substances that would cause defective light emission during operation
2Manufacturing precision
If the insulating layer is positioned close to the wire edge, then manufacturing precision is improved, but the insulating layer may chip off during air spraying
Solution Approach 1:
The patent applies beforehand cushioning by designing the insulating layer with a rounded end portion instead of a sharp edge, and positioning it at a controlled distance from the wire, which prevents chipping during air spraying while maintaining manufacturing precision
Solution Approach 2:
The insulating layer is designed with a rounded end portion having a specific curvature radius, eliminating sharp edges that would be prone to chipping during the air spraying process while maintaining precise positioning
3Reliability
If the insulating layer has a large contact area with the wire, then reliability is improved by preventing chipping, but device complexity increases
Solution Approach 1:
The patent applies local quality by providing the rounded end portion only at the specific location where chipping is most likely to occur during air spraying, rather than making the entire insulating layer complex, thus maintaining reliability while minimizing added complexity
Data Source
AI summary
A display apparatus includes a substrate, a wire having an inner edge including first and second portions, a first insulating layer covering a portion of the substrate, and a second insulating layer. The portion of the substrate covered by the first insulating layer is closer to a center of the substrate than the wire, the first insulating layer covers a part of the first portion of the wire and a part of the second portion of the wire, and a first end of the first insulating layer is disposed on the wire. The second insulating layer covers the first insulating layer and has a second end disposed on the wire. A distance between the first end and the second end covering the first portion of the wire is different from a distance between the first end and the second end covering the second portion of the wire.