Display Panel Cladding Layer for Exposed Wiring Corrosion
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Solution Overview
Problem
Current micro LED and mini LED display panels face line corrosion due to exposed metal wirings after test pads are cut, leading to abnormal performance.
Innovation Solution
A display panel design featuring a protective layer with a cladding layer that covers the exposed ends of signal wirings, using inorganic and parylene coatings to prevent water and oxygen exposure, thereby reducing corrosion risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If test pads are cut after cell test to enable panel assembly, then panel assembly efficiency is improved, but metal wirings become exposed and susceptible to corrosion
Solution Approach 1:
The patent applies preliminary action by forming the protective layer covering the metal wirings before the test pads are cut. This ensures that when the test pads are subsequently removed for assembly, the metal wirings are already protected from exposure to corrosive environments, thus preventing corrosion while enabling efficient panel assembly.
Solution Approach 2:
The patent introduces a protective layer as an intermediary substance between the metal wirings and the external environment. This protective layer acts as a barrier that prevents direct contact between the metal wirings and corrosive elements such as moisture and oxygen, thereby protecting the wirings from corrosion while allowing the test pads to be cut and removed.
2Ease of operation
If metal wirings are exposed after test pad removal, then test signal transmission is enabled, but water vapor and oxygen contact the wirings causing corrosion
Solution Approach 1:
The protective layer serves as an intermediary barrier that allows test signal transmission to occur while simultaneously blocking water vapor and oxygen from reaching the metal wirings. This resolves the contradiction by enabling ease of operation for test signal transmission while preventing harmful factor exposure.
Solution Approach 2:
The patent converts the potential harm of exposed metal wirings into a benefit by applying a protective layer that not only prevents corrosion but also maintains the electrical functionality for test signal transmission. The protective layer transforms the harmful exposure into a controlled environment that preserves both electrical performance and corrosion resistance.
3Reliability
If protective coatings are applied to cover exposed metal wirings, then corrosion resistance is improved, but manufacturing process complexity increases
Solution Approach 1:
The protective layer is formed as a preliminary step in the manufacturing process, before test pad removal and panel assembly. By integrating this protective coating step into the early stages of manufacturing, the process complexity is minimized and the corrosion resistance is established before the wirings become exposed.
Solution Approach 2:
The protective layer serves multiple functions simultaneously: it provides corrosion resistance to the metal wirings, maintains electrical insulation for test signal transmission, and prepares the surface for subsequent assembly operations. This multi-functionality reduces the need for additional separate processes, thereby limiting the increase in manufacturing complexity.
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 prevents line corrosion by enhancing the water and oxygen barrier properties of the display panel, ensuring reliable performance and extending the lifespan of the panels.
Implementation Method 1
the cladding layer has a water vapor transmission rate less than a water vapor transmission rate of the protective layer
Implementation Method 2
the cladding layer includes at least a first cladding layer, and the first cladding layer is a parylene coating or an inorganic coating
Data Source
AI summary
A display panel, a method of manufacturing the same, and a spliced display screen are disclosed. A driving substrate includes a plurality of first signal wirings and a plurality of light-emitting devices arranged in an array on the driving substrate. Each of the light-emitting devices is electrically connected to a corresponding one of the first signal wirings on the driving substrate. A protective layer covers the light-emitting devices and the driving substrate. One end of each of the first signal wirings is exposed at the protective layer to form an exposed end. The cladding layer covers the exposed end of the first signal wiring, so that the first signal wiring can be prevented from being exposed to cause line corrosion, thus alleviating a problem of line corrosion caused by exposed metal wirings in current display panels.