Display Base Layer Contrast for Real-Time Etching Detection
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Solution Overview
Problem
Current display device manufacturing lacks a method to determine the etch rate or etching defects in real-time, making it difficult to ensure proper exposure of the pad layer during the etching process, which can lead to process defects and reduced yield.
Innovation Solution
A display device design featuring a first base layer and a second base layer with different colors and light transmittance, where the second sub-base layer has a lower light transmittance than the first sub-base layer, allowing for real-time monitoring of etching completion by comparing the image clarity of the etched area with a reference value.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single uniform base layer is used, then the manufacturing process is simple, but real-time monitoring of etching completion is not possible
Solution Approach 1:
The base layer is divided into multiple sub-layers (first sub-base layer, second sub-base layer, third sub-base layer) with different light transmittances. This segmentation allows optical monitoring of etching progress through the stack, enabling real-time detection of etching completion while maintaining a manageable layered structure.
Solution Approach 2:
Different sub-layers are assigned different light transmittance properties (first sub-base layer has higher transmittance, second has lower transmittance, third has intermediate transmittance). This local quality differentiation creates optical contrast that enables visualization of etching progression through the base layer stack.
2Measurement precision
If the second sub-base layer has very low light transmittance, then etching monitoring is improved, but light transmission for display performance is reduced
Solution Approach 1:
The base layer is segmented into multiple sub-layers with graded light transmittances rather than using a single low-transmittance layer. The second sub-base layer provides monitoring contrast, while the first and third sub-base layers with higher transmittances ensure sufficient light transmission for display performance.
Solution Approach 2:
The light transmittance parameter is varied across different sub-layers instead of being uniform. The second sub-base layer has lower transmittance for monitoring, while other sub-layers maintain higher transmittance to balance monitoring needs with display optical performance.
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
Enables real-time determination of etching completion, reducing the risk of process defects and improving yield by clearly exposing the pad layer, thus facilitating stable electrical connections during the outer lead bonding process.
Implementation Method 1
A light transmittance of the second sub-base layer may be lower than a light transmittance of the first sub-base layer
Data Source
AI summary
A display device includes: a first base layer including opening; a pad layer disposed on the first base layer, the pad layer overlapping the opening; a second base layer disposed on the pad layer; a pixel circuit layer disposed on the second base layer; and light emitting elements disposed on the pixel circuit layer, the light emitting elements connected to the pixel circuit layer and included in pixels. A color of the first base layer is different from a color of the second base layer.