Display Panel Particle Removal Using Laser-Ablated Connecting Members
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Solution Overview
Problem
Display devices often suffer from signal transmission defects due to unintentional particles that can form shorts between adjacent pads during manufacturing, which are not effectively addressed by existing methods.
Innovation Solution
A method involving the use of a laser to irradiate the upper surface of a connecting member, removing the connecting member and any particles, and filling the resulting holes with a desiccant to prevent air and moisture penetration, thereby eliminating particle-induced defects and improving display quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manufacturing methods are used, then production efficiency is maintained, but particles remain between pads causing shorts and signal transmission defects
Solution Approach 1:
The laser irradiation process is performed as a preliminary action during manufacturing to remove particles before they can cause shorts. By proactively eliminating particles between pads through targeted laser irradiation, the method prevents future signal transmission defects while integrating seamlessly into the existing manufacturing workflow, thus maintaining productivity while improving reliability
Solution Approach 2:
The method converts the potentially harmful presence of particles into a beneficial quality control step. By using laser irradiation to target and remove particles that would otherwise cause shorts, the process transforms a manufacturing defect risk into an opportunity for enhanced product reliability without significant productivity loss
2Reliability
If laser irradiation is used to remove particles, then particle-induced shorts are prevented, but additional manufacturing steps are required
Solution Approach 1:
The method extracts the particle removal function as a distinct laser irradiation step from the conventional manufacturing process. By isolating this critical quality control action, the process efficiently targets and eliminates particles without requiring complete process redesign, thus preventing shorts while adding only the necessary minimal complexity
Solution Approach 2:
The laser acts as an intermediary tool that bridges the gap between conventional manufacturing methods and the need for particle removal. This intermediary approach allows particle elimination to be integrated into the existing manufacturing flow without requiring fundamental changes to the overall manufacturing system, thereby limiting the increase in process complexity
3Reliability
If connecting member is removed to eliminate particles, then shorts are prevented, but holes are created requiring desiccant filling
Solution Approach 1:
The method converts the harmful effect of particles into a beneficial quality control step. By using laser irradiation to target and remove particles that would otherwise cause shorts, the process transforms a manufacturing defect risk into an opportunity for enhanced product reliability without significant productivity loss
Solution Approach 2:
The method extracts the particle removal function as a distinct laser irradiation step from the conventional manufacturing process. By isolating this critical quality control action, the process efficiently targets and eliminates particles without requiring complete process redesign, thus preventing shorts while adding only the necessary minimal 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
This approach effectively prevents shorts between pads, enhances display quality, and can be applied to various display device structures without transmitting through substrates, reducing the non-display area and ensuring reliable signal transmission.
Implementation Method 1
irradiating a laser to an upper surface of the connecting member overlapping at least a part of the particle, removing the connecting member overlapping a region to which the laser is irradiated, removing the particle overlapping a region to which the laser is irradiated
Data Source
AI summary
A method for manufacturing a display device includes checking a particle positioned between a display panel and a connecting member, irradiating a laser to an upper surface of the connecting member overlapping at least a part of the particle, removing the connecting member overlapping a region to which the laser is irradiated, removing the particle overlapping a region to which the laser is irradiated, and disposing a desiccant in a hole formed by removing the connecting member and the particle.