Display Backplane Protective Trenches for Residue-Free Peripheral Areas
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Solution Overview
Problem
Current display device manufacturing methods face challenges in achieving reliable and efficient production, particularly in the formation of protective layers and the separation of cells, which can lead to process residues and reduced visibility in the peripheral areas.
Innovation Solution
The proposed solution involves a display device design with a backplane structure including a base layer, outer via layer, and protective layers, where the outer protective layer has holes in the active area and recessed trenches in the peripheral area, and a manufacturing method that forms a support layer and ink layer to facilitate cell separation without discontinuity, using a halftone mask for trench formation and UV curing for layer hardness control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional protective layer structure is used in display device manufacturing, then the manufacturing process is simpler, but process residues remain in the peripheral areas reducing visibility and reliability
Solution Approach 1:
The protective layer is divided into multiple distinct layers: a first protective layer covering the active area and a second protective layer covering the peripheral area. This segmentation allows each layer to be optimized for its specific function, enabling complete removal of process residues in the peripheral area while maintaining protection where needed, thus improving manufacturing reliability without excessive complexity
Solution Approach 2:
Different regions of the display device receive different protective treatments. The first protective layer provides full coverage in the active area where pixels require protection, while the second protective layer in the peripheral area is designed to be completely removable to eliminate process residues. This local differentiation ensures high visibility and reliability in peripheral areas while maintaining necessary protection in active areas
2Illumination intensity
If the outer protective layer is completely removed in the peripheral area, then visibility is improved, but the structural integrity during manufacturing may be compromised
Solution Approach 1:
The second protective layer is designed and formed in advance specifically for the peripheral area with the intention of complete removal after manufacturing. This preliminary placement provides the necessary structural support during the manufacturing process, and its subsequent complete removal achieves perfect visibility without residues, as the layer served its structural purpose temporarily
Solution Approach 2:
The protective layer system is segmented into a first protective layer that remains for structural integrity and a second protective layer that is temporarily present for manufacturing support but is completely removed afterward. This segmentation allows the temporary second layer to provide necessary strength during manufacturing while enabling complete removal to achieve perfect visibility in the peripheral area
3Productivity
If support layer and ink layer formation is simplified, then manufacturing efficiency increases, but cell separation discontinuity occurs reducing product quality
Solution Approach 1:
A support layer is introduced as an intermediary element during the manufacturing process. This support layer provides a foundation for forming the ink layer and ensures continuous cell separation throughout the manufacturing process. The support layer acts as a mediator that enables efficient manufacturing while maintaining the critical continuity of cell separation, preventing quality defects
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 enhances the reliability and visibility of the display device by preventing process residues in the peripheral areas and ensuring uniform ink layer formation, improving the manufacturing process efficiency and display quality.
Implementation Method 1
using a halftone mask for trench formation and UV curing for layer hardness control
Data Source
AI summary
A display device includes an active area and a peripheral area adjacent to the active area, the display device including: a base layer; and a backplane structure including a backplane layer on the base layer, an outer via layer on the backplane layer, and an outer protective layer on the outer via layer, wherein the outer protective layer includes a first outer protective layer having holes exposing the outer via layer in the active area, and a second outer protective layer having a plurality of trenches recessed toward the outer via layer without exposing the outer via layer in the peripheral area.