Stacked Metal Lines in Display Panels for Shorting Prevention
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Solution Overview
Problem
The manufacturing of display panels with ultra slim bezels and increased metal line thickness leads to irregular photoresist coating thickness, resulting in incomplete exposure and shorting between stacked metal lines, affecting the performance of display devices.
Innovation Solution
A display panel design with a first metal layer and a second metal layer, where the second metal lines have orthogonal projections on the first metal layer, positioned in areas of the first gaps, and the layers are shifted relative to each other to prevent shorting, along with an insulation layer to cover and fill gaps, and a method involving shifted mask plates for precise photolithography to avoid incomplete exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the metal line thickness is increased to reduce loading of data lines and drive scan lines, then the loading is reduced, but the photoresist coating thickness becomes irregular leading to incomplete exposure and shorting
Solution Approach 1:
The patent transitions from a single-layer metal structure to a multi-layer stacked metal structure. By adding vertical dimensionality with multiple metal layers, the design achieves reduced loading on data lines and drive scan lines while maintaining manufacturability through careful control of layer thickness and spacing
Solution Approach 2:
The patent applies preliminary protective actions by introducing an insulation layer between stacked metal lines and using optimized photoresist coating procedures before the shorting problem can occur. The insulation layer is deposited in advance to prevent direct contact between metal layers, and the photoresist coating is optimized beforehand to ensure uniform thickness even on thick metal structures
2Length of moving object
If the line width and line spacing are made extremely small for ultra slim bezel design, then the bezel thickness is reduced, but the photoresist coating becomes irregular causing incomplete exposure and shorting
Solution Approach 1:
The patent uses stacked metal layers arranged in different vertical levels to achieve compact routing within the fan-out zone. This three-dimensional arrangement allows ultra-slim bezel design by reducing the horizontal footprint of wirings while maintaining adequate spacing for manufacturing
Solution Approach 2:
The patent introduces an insulation layer as an intermediary substance between adjacent metal lines in the fan-out zone. This insulation layer acts as a mediator that maintains electrical isolation between closely spaced metal lines, enabling ultra-slim bezel design while preventing shorting through the intermediate protective barrier
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
This solution effectively prevents shorting between metal lines during manufacturing, ensuring complete exposure and reducing defects in display panels, meeting the requirements for high-resolution, large-size, and ultra slim bezel designs.
Implementation Method 1
a first mask plate is arranged on a first position to form, through exposure and development, the first metal lines... a second mask plate is arranged on a second position to form, through exposure and development, the second metal lines
Data Source
AI summary
A display panel includes a first metal layer and a second metal layer sequentially stacked. The first metal layer includes a plurality of first metal lines and first gaps arranged between the first metal lines. The second metal layer includes a plurality of second metal lines arranged in a spaced manner. The second metal lines have an extension direction that is identical to an extension direction of the first metal lines. The second metal lines and the first metal lines are arranged to stagger, in position, with respect to each other. The second metal lines have orthogonal projections on the first metal layer that are located in areas of the first gaps in order to prevent shorting between the second metal lines in a process of manufacturing the second metal lines. A method for manufacturing the display panel and a display device are also provided.