Display Substrate Dummy Conductor for Uniform LED Mounting Pressure
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Solution Overview
Problem
Existing LED display devices face issues with non-uniform pressure distribution during the mounting process due to a substrate with a less flat second surface, leading to defective mounting of LEDs and reduced image quality and manufacturing yield.
Innovation Solution
Incorporating a protrusion or dummy conductor on the second surface of the substrate, which is designed to be electrically insulated from the wiring and terminals, improves the substrate's rigidity and ensures uniform pressure distribution during LED mounting by acting as a cushion and stabilizing the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the substrate second surface is made flat to ensure uniform pressure distribution during LED mounting, then manufacturing precision and reliability improve, but the substrate structure becomes more complex due to the need for additional protrusions or dummy conductors
Solution Approach 1:
The patent employs protrusions or dummy conductors on the substrate second surface that are electrically insulated from the wiring and terminals. These structures serve as sacrificial elements during the mounting process to ensure uniform pressure distribution, accepting their role as non-functional additions that simplify the overall manufacturing process while maintaining structural integrity.
Solution Approach 2:
The protrusions or dummy conductors act as intermediary elements between the mounting pressure and the substrate structure. By positioning these elements on the second surface, they mediate the pressure distribution during LED mounting, preventing direct transmission of non-uniform pressure to the functional wiring and terminals, thereby ensuring consistent mounting quality.
2Reliability
If protrusions or dummy conductors are added to the substrate second surface to improve flatness and pressure distribution, then LED mounting reliability improves, but the device complexity increases
Solution Approach 1:
The protrusions or dummy conductors are designed as simple, electrically insulated structures that serve their purpose during mounting and then become part of the final structure. Their simplicity and electrical insulation make them low-cost additions that significantly improve mounting reliability without requiring complex integration or additional functional systems.
3Manufacturing precision
If the substrate is made more rigid to maintain flatness during mounting, then manufacturing precision improves, but the substrate becomes more susceptible to deformation or cracking under stress
Solution Approach 1:
The patent applies local quality by adding protrusions or dummy conductors only on the second surface of the substrate, rather than making the entire substrate thicker or more rigid throughout. This localized approach provides the necessary flatness and structural support during mounting while preserving the overall flexibility and stress distribution characteristics of the substrate, preventing deformation and cracking.
Data Source
AI summary
A display device includes a substrate including a first surface and a second surface opposite to the first surface, a display on the first surface, a first wiring pad located on the second surface and electrically connected to the display, an external connection terminal on the second surface, connection wiring located on the second surface and electrically connecting the first wiring pad and the external connection terminal, and a dummy conductor being a protrusion on the second surface. The protrusion overlaps none of the first wiring pad, the external connection terminal, and the connection wiring in a plan view.