Display Panel Gate Repair Layout for Via Connection Failures
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Solution Overview
Problem
High-resolution LCD panels face issues with poor contact or connection failure between gate lines and gate connection lines due to dense connection vias and process fluctuations, leading to reduced product yield and scrap rates, especially in narrow border/no border display panels where current detection technologies fail to detect these failures.
Innovation Solution
Incorporating gate repair lines and connection repair lines arranged in specific correspondence with gate lines and connection lines, allowing for targeted welding during a lighting test to establish electrical connections and prevent failures, thereby maintaining effective gate line functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If connection vias are made very small to reduce aperture ratio influence in high-resolution panels, then the aperture ratio is improved, but the manufacturing precision and reliability of gate line connections deteriorate due to process fluctuations
Solution Approach 1:
The patent applies preliminary action by pre-establishing repair lines (gate repair lines and connection repair lines) during the manufacturing process before any connection failures occur. These repair lines are positioned to intersect with gate lines and connection lines at predetermined points, allowing for post-manufacturing repairs without requiring complete panel replacement. This proactive preparation resolves the contradiction by maintaining small via sizes for high aperture ratios while providing a safety mechanism to compensate for potential connection failures caused by process fluctuations.
Solution Approach 2:
The patent changes the structural parameters of the panel by introducing additional conductive elements (repair lines) that can alter the electrical connection path. When connection failures occur, the repair lines provide alternative conduction paths by establishing new electrical connections at intersection points. This parameter change allows the system to maintain reliability despite the small via sizes required for high-resolution displays with high aperture ratios.
2Productivity
If gate repair lines and connection repair lines are added to enable post-manufacturing repairs, then the product yield is improved, but the device complexity increases
Solution Approach 1:
The patent merges the repair functionality with the existing gate driver circuit structure by integrating repair lines into the same metal layers and routing structures as the functional lines. The gate repair lines are formed in the same metal layer as gate lines, and connection repair lines are formed in the same metal layer as connection lines, allowing shared manufacturing processes and reducing overall device complexity despite the added repair capability.
Solution Approach 2:
The repair lines serve multiple functions: they act as both functional signal transmission paths and as repair pathways for failed connections. The same conductive structures that transmit gate signals also provide alternative paths for repairing defective connections, eliminating the need for separate dedicated repair structures and reducing the net increase in device complexity while improving product yield.
Data Source
AI summary
A display panel and a method of manufacturing the display panel are provided. Wherein, a display region of the display panel includes a plurality of gate lines extending laterally and a gate repair line, a plurality of gate connection lines extending longitudinally to a non-display region, and a first connection repair line extending longitudinally. The gate repair line is connected to the first connection repair line in a one-to-one correspondence, each of the gate repair line is provided with a plurality of first connection repair points, and each of the first connection repair lines is provided with a plurality of second connection repair points.