Display Panel Dummy Pattern Area Mitigates Loading Effect
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Solution Overview
Problem
The loading effect in wet processes for panel display manufacturing leads to pattern irregularities in the boundary areas of liquid crystal panels, causing defective image display due to differences in photo-resist and metal layer etching, affecting luminance, view angle, response time, and charging characteristics.
Innovation Solution
A display panel design that includes a dummy pattern area without display functionality along the boundary between the active and vacant areas, maintaining equal solution concentration at the intersection and gradually decreasing concentration towards the vacant area to mitigate the loading effect, ensuring uniform patterns in the active area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wet process lithography is used for photo-resist and metal layer etching, then the manufacturing process is simple and cost-effective, but the loading effect causes pattern irregularities in boundary areas between active and vacant regions
Solution Approach 1:
The panel is divided into three distinct regions: active area, vacant area, and a newly introduced dummy pattern area. This segmentation isolates the loading effect to the dummy pattern area, preventing it from affecting the active area patterns, thereby maintaining manufacturing precision while preserving the simplicity of the wet process manufacturing method
Solution Approach 2:
The dummy pattern area acts as an intermediary buffer zone between the active area and vacant area. It absorbs the loading effect through controlled ingredient consumption and diffusion, serving as a mediator that protects the active area from pattern irregularities while allowing the use of simple wet process manufacturing
2Productivity
If the active area has small photo-resist area requiring lithography, then the display functionality is optimized, but the loading effect causes insufficient lithography result in boundary areas leading to pattern irregularity
Solution Approach 1:
The dummy pattern area is designed in advance to preemptively consume lithography ingredients through controlled diffusion. This preliminary action ensures that by the time the actual active area patterns are formed, the ingredient concentration has stabilized, preventing pattern irregularities in the boundary areas and maintaining manufacturing precision
Solution Approach 2:
Different regions of the panel are given different qualities: the active area maintains high pattern density for display functionality, the vacant area has no patterns, and the dummy pattern area has controlled pattern density specifically designed to manage ingredient diffusion. This local differentiation allows the active area to achieve optimal display performance while the dummy area compensates for loading effects
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
The dummy pattern area acts as a buffer, preventing the loading effect from affecting the active area, resulting in normal and uniform patterns across the display panel, thus eliminating pattern irregularities and maintaining image quality.
Implementation Method 1
The solution has a diffusion effect to maintain the same concentration everywhere in the solution. When differences exist in the thin film patterns on the substrate, the ingredient in the solution will diffuse from high concentration place to lower concentration place during the lithography or etching process
Data Source
AI summary
Provided is a display panel, which includes an active area and a vacant area surrounding the active area, and a dummy pattern area without display functionality being along a boundary between the active area and the vacant area. Also provided are a manufacturing method of a display panel and a panel display device. A dummy pattern area is provided along a boundary of an active area to withstand a loading effect and to ensure the active area is not affected by the loading effect and display patterns are normal and uniform.