Display Panel Alignment via Cross-Surface Optical Patterns
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Solution Overview
Problem
The challenge in manufacturing large-size display panels is accurately splicing multiple panels together to form a seamless and reliable large-size display device, as existing methods struggle with alignment accuracy and the inclusion of a narrow or frameless design.
Innovation Solution
A manufacturing method for display panels involves forming a light-shielding positioning layer with alignment patterns on one surface and a transparent positioning layer with overlapping alignment patterns on the opposite surface, allowing for self-alignment and improved accuracy through an exposure, developing, and etching process, thereby enhancing the reliability of connections between pads on both surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple display panels are spliced together to form large-size display devices, then the display size can be increased beyond substrate limitations, but alignment accuracy between panels deteriorates and framing issues arise
Solution Approach 1:
The patent introduces alignment patterns as intermediary reference elements that mediate the alignment process between multiple display panels. These patterns are formed on both front and rear surfaces of the substrate, serving as intermediate reference points that guide the splicing process and ensure accurate positioning without requiring direct visual alignment between panels.
Solution Approach 2:
The patent replaces traditional mechanical alignment methods with a light-based optical alignment system. By using light beams to illuminate alignment patterns and capturing their images for processing, the system substitutes mechanical measurement and adjustment with optical field-based positioning, achieving higher precision in aligning multiple display panels.
2Ease of manufacture
If traditional alignment methods are used for splicing display panels, then the manufacturing process is simpler, but alignment reliability and connection capability deteriorate
Solution Approach 1:
The patent implements a feedback mechanism in the alignment process by capturing images of alignment patterns, processing them to calculate precise positional relationships, and using this information to guide the splicing operation. This closed-loop feedback system ensures high connection reliability by verifying alignment accuracy before final panel bonding.
Solution Approach 2:
The patent performs preliminary alignment pattern formation on both surfaces of the substrate before the actual panel splicing operation. By pre-establishing the alignment reference system and calculating positional relationships in advance, the method ensures that when splicing occurs, the panels can be accurately positioned based on pre-computed alignment data, enhancing connection reliability.
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 method improves alignment accuracy and reliability by ensuring that alignment patterns on both surfaces overlap, reducing the likelihood of misalignment and enhancing the connection structure's capability, ultimately facilitating the creation of seamless and narrow-framed display devices.
Implementation Method 1
An exposure process is performed, such that a light beam passes through the at least one first alignment pattern to penetrate through the substrate and the transparent material layer to the photoresist layer
Data Source
AI summary
A manufacturing method of a display panel includes providing a substrate having a first surface and a second surface opposite to the first surface; forming a high-shielding position layer on the first surface, wherein the light-shielding positioning layer has at least one first alignment pattern; forming a transparent material layer on the second surface; forming a photoresist layer on the transparent material layer; performing an exposure process, such that a light beam passes through the at least one first alignment pattern to penetrate through the substrate and the transparent material layer to the photoresist layer; performing a developing process to pattern the photoresist layer and form a patterned photoresist layer; and performing an etching process to pattern the transparent positioning layer having at least one second alignment pattern. In a direction perpendicular to the substrate, at least one first alignment pattern overlaps with at least one second alignment pattern.