Display Pad Energy-Absorbing Layer for Laser Overheating Control
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Solution Overview
Problem
During the laser heating process in display device manufacturing, certain portions of the conductive structures can be overheated, leading to cracks, disconnections, and dark dot defects, which reduce the display quality.
Innovation Solution
The implementation of layers with lower absorptivity relative to the laser are disposed along laser beam paths to cover conductive structures, acting as energy-absorbing layers to block and absorb laser energy, thereby reducing heat conduction impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser heating is performed to bond light-emitting elements to metal pads, then bonding efficiency is improved, but conductive structures may be overheated causing cracks and disconnections
Solution Approach 1:
An energy-absorbing layer is introduced as an intermediary component between the laser beam and the conductive structures. This layer selectively absorbs laser energy to protect the source/drain regions from overheating while allowing the bonding process to proceed. The energy-absorbing layer acts as a mediator that manages the laser energy distribution to prevent harmful thermal effects on the conductive structures.
Solution Approach 2:
The patent applies different material properties to different regions: the energy-absorbing layer is specifically positioned to cover the source/drain regions with high laser absorptivity, while other areas maintain their original properties. This localized application of specific material characteristics allows selective protection of vulnerable conductive structures without affecting the overall bonding process efficiency.
2Productivity
If laser heating is applied to mass transfer light-emitting elements, then manufacturing efficiency is improved, but dark dot defects appear in the display area
Solution Approach 1:
The energy-absorbing layer serves as a protective intermediary that prevents excessive laser heating of the conductive structures in the display area. By absorbing the laser energy before it reaches the source/drain regions, this layer prevents the formation of dark dot defects while allowing the mass transfer and bonding processes to continue efficiently.
Solution Approach 2:
The energy-absorbing layer is positioned in advance to counteract the harmful thermal effects of laser heating before they can occur. By being pre-placed over the vulnerable conductive structures, it proactively prevents overheating and the subsequent formation of dark dot defects, rather than addressing the problem after it occurs.
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
This approach effectively reduces dark dot defects and improves display quality by mitigating the overheating of conductive structures during laser heating processes.
Implementation Method 1
An absorptivity of a material of the energy-absorbing layer with respect to a laser is lower than an absorptivity of a material of the source/drain with respect to the laser
Data Source
AI summary
A display device includes a substrate, a switching element, a first insulating layer, a first metal layer, and an energy-absorbing layer. The switching element is on the substrate and has a source/drain. The first insulating layer covers the switching element and has a first opening. The first metal layer is on the first insulating layer and extends through the first opening. The energy-absorbing layer is over the first metal layer. A first orthographic projection area of the first opening projected on the substrate is within a second orthographic projection area of the energy-absorbing layer projected on the substrate. A laser reflectivity of a material of the energy-absorbing layer is higher than a laser reflectivity of a material of the source/drain. A laser absorptivity of the material of the energy-absorbing layer is lower than a laser absorptivity of the material of the source/drain.