Display Panel Lead Layout for Low-Damage Laser Etching

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Solution Overview

Problem

The existing manufacturing processes for display panels using micro LEDs and mini LEDs face issues with laser damage to the film layers and devices due to the thickness mismatch between the connecting leads and the film layers, leading to reliability problems and impaired display performance.

Innovation Solution

A manufacturing method for display panels that involves forming connecting leads using a conductive layer patterned by laser etching, with specific gap configurations to minimize laser damage by irradiating from multiple directions, ensuring the thickness of the connecting leads aligns with the film layers, thereby reducing damage to the driving circuit and light-emitting devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If connecting leads are formed by laser etching to match the thickness of film layers, then manufacturing precision is improved, but laser damage to the film layers and devices occurs

Engineering Contradiction:
Improvethickness matching of connecting leads and film layersVSAvoidlaser damage to film layers and devices
Core Design Contradiction:
Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The laser etching process is divided into multiple sequential steps with different laser parameters. The first step uses lower power to create an initial groove, the second step continues etching with adjusted parameters, and the third step completes the thickness matching. This segmentation allows precise control of the etching depth while minimizing cumulative laser damage to the film layers and light-emitting devices.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Before completing the connecting lead formation, the method performs preliminary actions including forming a first groove, then a second groove, and finally a third groove in sequence. Each preliminary step prepares the structure for the next step, allowing the laser to gradually remove material with reduced energy concentration, thereby preventing sudden excessive heating and damage to sensitive components.

Inventive Principle:
Principle #10Preliminary action

2Manufacturing precision

If laser etching is used to form connecting leads, then manufacturing precision is improved, but reliability deteriorates due to damage to driving circuit and light-emitting devices

Engineering Contradiction:
Improveconnecting lead thickness consistencyVSAvoidintegrity of driving circuit and light-emitting devices
Core Design Contradiction:
Manufacturing precisionVSReliability

Solution Approach 1:

The laser etching process is segmented into three distinct steps, each with controlled laser power and duration. This segmentation prevents excessive energy concentration that would damage the driving circuit and light-emitting devices, while still achieving the required precision in connecting lead thickness. Each step contributes to the final precise shape without compromising component reliability.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The method applies partial laser etching actions in sequence rather than a single excessive action. Each laser step removes only the necessary amount of material for that stage, avoiding over-etching and thermal damage to sensitive components. The cumulative effect of partial actions achieves the target precision while preserving component integrity.

Inventive Principle:
Principle #16Partial or excessive action

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 method effectively reduces laser-induced damage to the film layers and devices, enhancing the reliability and display quality of the panels by maintaining consistent signal transmission and light emission.

Implementation Method 1

a cross section of the conductive layer is removed by the laser to form a plurality of connecting leads

Methodology Applied
Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS20260033071A1Display Panel and Manufacturing Method Therefor, Display Device and Tiled Display Device
Publication Date: 2026.01.29 BOE MLED TECH CO LTD
  • US20260033071A1 patent drawing
  • US20260033071A1 patent drawing
  • US20260033071A1 patent drawing

AI summary

A display panel includes a substrate, a driving circuit layer, first bonding electrodes, and connecting leads. The substrate includes a first surface, a second surface and a selected side surface. The first bonding electrodes are in a peripheral area of the first surface. Each connecting lead includes a first part, a second part and a third part on the first, selected side and second surfaces, respectively. The first part is electrically connected to one first bonding electrode. The connecting leads have first gaps including first-type gap areas. First parts of two adjacent connecting leads have a first gap. A first-type gap area includes a first sub-gap area and a second sub-gap area, the first sub-gap area being closer to the selected side surface than the second sub-gap area. Along the first direction, a dimension of the first sub-gap area is less than a dimension of the second sub-gap area.