Display Panel Electrode Layout for Reliable Mini LED Coupling
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Solution Overview
Problem
The manufacturing yield of mini LED and micro LED display screens is low due to the immaturity of mass transfer technology, which results in poor connections between wires and electrodes caused by small contact areas, leading to displacement issues.
Innovation Solution
A display panel design with a light-emitting assembly and a driving assembly, where first and second conductive members electronically couple electrodes with larger surface areas, reducing the likelihood of misalignment and improving coupling probability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire bonding is used to connect LEDs with TFT array substrate, then electronic coupling is achieved, but contact areas are small and connection areas are small, leading to poor display and displacement issues
Solution Approach 1:
The patent segments the connection structure into multiple components: a connection substrate with connection electrodes, conductive adhesive layers, and wire bonds. This segmentation allows each component to perform its function optimally - the connection substrate provides large contact area, the conductive adhesive ensures reliable electrical connection, and the wire bonds provide mechanical support and electrical connection to the TFT substrate.
Solution Approach 2:
The patent transitions from traditional wire bonding (point contact in 3D space) to a planar connection structure where the connection substrate and conductive adhesive create a 2D connection area. This dimensional change from point-to-point wiring to area-to-area connection significantly increases the contact and connection areas, improving both reliability and alignment precision.
2Productivity
If mass transfer technology is used to transfer countless LEDs to TFT array substrate, then display screen assembly is completed, but the technology is immature resulting in poor connections and displacement
Solution Approach 1:
The patent merges the LED connection process with the TFT substrate assembly process by integrating the connection substrate as an intermediate layer. Instead of transferring individual LEDs separately and then connecting them, the connection substrate is transferred together with the LED array, ensuring that connection electrodes are properly aligned and connected to each LED in a single integrated process.
Solution Approach 2:
The connection substrate acts as an intermediary between the LED array and the TFT array substrate. It provides connection electrodes that interface with both the LEDs and the TFT substrate, facilitating reliable electrical connection while allowing the mass transfer process to proceed without direct contact between individual LEDs and the TFT substrate, thereby improving connection reliability.
3Ease of manufacture
If small contact areas are used in wire bonding, then manufacturing process is simple, but connection reliability is poor due to small contact and connection areas
Solution Approach 1:
The patent performs preliminary action by pre-configuring the connection substrate with connection electrodes and conductive adhesive patterns before transferring it to the LED array. This preliminary preparation ensures that when the mass transfer occurs, the connection electrodes are already positioned and sized to provide large contact areas, eliminating the need for complex post-assembly adjustments while ensuring reliable connections.
Data Source
AI summary
A display panel, a display screen, and a manufacturing method of a display screen are provided. The display panel includes a light-emitting assembly, a driving assembly, multiple first conductive members, and multiple second conductive members. The light-emitting assembly includes multiple light-emitting units, where each of the multiple light-emitting units includes a first electrode and a second electrode spaced apart from the first electrode, and the first electrode surrounds the second electrode. The driving assembly includes multiple driving units, where one of the multiple driving units is disposed in correspondence with one of the multiple light-emitting units, and different driving units correspond to different light-emitting units. Each of the multiple driving units includes a third electrode and a fourth electrode spaced apart from the third electrode, and the third electrode surrounds the fourth electrode. Each of the multiple first conductive members couples the first electrode with the third electrode.