Display Panel Pad Insulation to Prevent Silver Particle Defects
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Solution Overview
Problem
The formation of silver particles during the pixel etching process in display panels due to the reaction between an etchant and exposed metal materials of pads leads to dark spot defects, affecting display quality.
Innovation Solution
A display panel structure is designed with insulating layers and conductive patterns to prevent silver particle formation, including a base layer, circuit layer, and light emitting element layer, with specific insulating patterns and openings to protect the pads, and a manufacturing method that involves forming conductive patterns, insulating layers, and using a hard mask to remove excess material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the pixel etching process uses an etchant to remove material, then the pixel structure is formed, but silver particles form due to reaction between the etchant and exposed metal pad materials causing dark spot defects
Solution Approach 1:
An insulating layer is introduced as an intermediary between the metal pad and the etchant. This insulating layer prevents direct contact between the etchant and metal pad, thereby eliminating the harmful chemical reaction that produces silver particles, while still allowing the etching process to proceed to form the pixel structure.
Solution Approach 2:
The insulating layer is formed on the metal pad before the pixel etching process. This preliminary protective action prevents the harmful reaction from occurring in the first place by blocking the etchant from contacting the metal pad surface during the etching operation.
2Object-generated harmful factors
If the insulating layer completely covers the pad area, then silver particle formation is prevented, but the pad cannot be electrically connected to external circuits
Solution Approach 1:
The insulating layer is applied selectively to specific regions rather than uniformly across the entire pad area. By controlling the spatial distribution and thickness of the insulating layer, the solution maintains protection in areas where etching occurs while preserving exposed metal regions for electrical connections.
Solution Approach 2:
The pad structure is divided into different functional zones: covered regions where the insulating layer prevents etchant contact and silver particle formation, and exposed regions where metal remains accessible for electrical connections. This segmentation allows simultaneous achievement of both protection and connectivity requirements.
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
Prevents dark spot defects by inhibiting silver particle formation, thereby enhancing display quality and reliability.
Implementation Method 1
silver particles from being formed through a reaction between an etchant and a metal material of pads
Data Source
AI summary
A display device includes a display panel including a display area, a non-display area adjacent to the display area and including a pad area, a circuit layer in the display area and the pad area, and a light emitting element in the display area. The circuit layer includes a first conductive pattern in the pad area, an insulating layer on the first conductive pattern and in which is defined an opening exposing the first conductive pattern to outside the insulating layer, and a first insulating pattern which is on the insulating layer and extends into the opening to be on a top surface of the first conductive pattern.