Display Panel Side-Lead Protection for Narrow-Bezel Tiled Displays
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Solution Overview
Problem
Existing display technologies face challenges in minimizing the bezel width of display apparatuses, leading to visible seams when tiled, which affects the display effect and longevity due to corrosion of side leads.
Innovation Solution
A display panel design incorporating a backplane with side surfaces, connecting leads that pass through selected side surfaces, a first protective layer, and a reflective layer to protect the connecting leads from corrosion and facilitate precise laser cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the bezel width is reduced to achieve narrower seams in tiled displays, then the display effect is improved, but the connecting leads become exposed and susceptible to corrosion
Solution Approach 1:
The connecting lead is nested within a protective layer structure that includes a first protective layer covering the lead and a reflective layer covering portions of the first protective layer. This nested configuration protects the connecting lead from corrosion while maintaining a narrow bezel width, as the protective layers are integrated within the existing structure rather than adding external width.
Solution Approach 2:
The protective function is achieved by transitioning from a two-dimensional surface coating to a multi-layered three-dimensional structure. The first protective layer and reflective layer create vertical depth (z-dimension) to protect the connecting lead, allowing the horizontal bezel width to remain narrow while providing adequate corrosion protection through the stacked layer configuration.
2Length of stationary object
If the connecting leads are exposed to reduce bezel width, then the display apparatus achieves narrower seams, but the service life is reduced due to corrosion
Solution Approach 1:
The first protective layer and reflective layer are formed on the connecting lead before final assembly and before the product reaches the user. This preliminary protection ensures the connecting lead is already shielded from corrosion at the time of manufacturing, preventing future degradation and extending service life while maintaining the narrow seam design.
Solution Approach 2:
The protective layer structure acts as a preemptive shield against corrosion, environmental damage, and mechanical stress. By providing this protective cushioning before the product is put into service, the connecting lead is protected from future harmful effects, ensuring long-term reliability and extended service life in the narrow bezel configuration.
3Reliability
If protective layers are added to protect connecting leads, then corrosion resistance is improved, but the manufacturing complexity increases
Solution Approach 1:
The formation of the first protective layer and reflective layer is merged with existing manufacturing processes. The protective layers are formed using the same deposition and patterning equipment already used for other conductive and functional layers in the display structure, combining multiple functions into a single integrated process flow rather than adding separate dedicated manufacturing steps.
Solution Approach 2:
The first protective layer serves multiple functions simultaneously: it provides corrosion protection for the connecting lead, acts as an adhesive layer for the reflective layer, and contributes to the overall structural integrity of the narrow bezel region. This multi-functionality reduces the need for additional specialized layers or processes, simplifying the overall manufacturing complexity.
4Reliability
If the reflective layer is applied to protect connecting leads, then the protective function is enhanced, but the material and processing requirements increase
Solution Approach 1:
The reflective layer uses standard metal materials (such as aluminum, silver, or copper) with thicknesses in the range of tens to hundreds of nanometers, which are conventional parameters already established in display manufacturing. These parameter choices balance protective effectiveness with ease of deposition using existing sputtering or evaporation equipment, avoiding the need for exotic materials or specialized processing conditions.
Solution Approach 2:
The reflective layer is selectively applied only to portions of the first protective layer that correspond to the connecting lead regions, rather than coating the entire display panel. This localized application reduces material consumption and processing time while providing protection precisely where needed, maintaining ease of manufacture while ensuring adequate protective function.
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 solution effectively reduces the bezel width, minimizes visible seams in tiled displays, and prolongs the service life of the display panel by protecting the connecting leads from corrosion.
Implementation Method 1
a reflective layer is formed. The reflective layer includes at least a first portion covering a portion of the first protective layer located on the selected side surface
Data Source
AI summary
A display panel includes: a backplane, a plurality of light-emitting devices, a plurality of connecting leads, a first protective layer and a reflective layer. The backplane includes a first main surface, a second main surface, and a plurality of side surfaces. At least one side surface is as a selected side surface. The plurality of light-emitting devices are disposed on the second main surface and are electrically connected to the plurality of connecting leads. The plurality of connecting leads are disposed on the first main surface, the selected side surface and the second main surface, and each connecting lead sequentially passes through the selected side surface and the second main surface from the first main surface. The first protective layer covers the plurality of connecting leads. The reflective layer includes at least a first portion covering a portion of the first protective layer on the selected side surface.