Display Substrate Protective Structure for Ultra-High PPI Yield
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Solution Overview
Problem
In ultra-high pixels-per-inch (PPI) display products, the small size of film layers in the display region leads to defects such as cracking of the active layer at the edges due to light diffraction and catalyst density issues during the exposure and development processes, resulting in serious defects and reduced product yield.
Innovation Solution
A display substrate design that includes a protective structure in the frame region, made of the same material as the gate, first electrode, or active layer, which surrounds the display region to prevent diffraction effects and maintain normal catalyst density, thereby reducing line breakage and improving yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the pixel size is reduced to achieve ultra-high PPI, then the display resolution is improved, but the film layer size becomes too small leading to cracking and defects
Solution Approach 1:
A protective structure is introduced as an intermediary element between the display region and the frame region. This protective structure, made from the same material as the gate electrode or active layer, acts as a mediator that prevents harmful diffraction effects from reaching the display region while maintaining the ultra-high PPI design. The protective structure serves as a buffer zone that protects the fragile film layers in the display region.
Solution Approach 2:
The protective structure is formed in advance during the manufacturing process, before the final display region patterns are completed. By establishing this protective barrier early in the process, the film layers in the display region are pre-protected from diffraction effects and catalyst density variations that would otherwise cause cracking during subsequent exposure and development steps.
2Ease of manufacture
If the protective structure is made from the same material as the gate or active layer, then the manufacturing process is simplified, but the material consumption increases
Solution Approach 1:
The protective structure is merged with the existing gate electrode or active layer material layers, forming them simultaneously in the same manufacturing step. This consolidation eliminates the need for separate material deposition processes, simplifies the manufacturing workflow, and reduces overall material consumption by utilizing the same material source for both protective and functional layers.
3Reliability
If the protective structure completely surrounds the display region, then the protection effect is maximized, but the device complexity increases
Solution Approach 1:
The protective structure is segmented into multiple discrete regions corresponding to different sides of the display region. Rather than forming one continuous surrounding structure, the protective layers are divided into separate segments that can be independently formed and controlled, reducing structural complexity while maintaining comprehensive protection through the combined effect of all segments.
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 protective structure effectively isolates the display region from diffraction effects and catalyst density variations, significantly reducing the occurrence of line breakage and enhancing the development process, resulting in improved product quality and yield.
Implementation Method 1
the small size of film layers in the display region leads to defects such as cracking of the active layer at the edges due to light diffraction
Data Source
AI summary
The present disclosure provides a display substrate and a display apparatus. The display substrate includes a base substrate, including a display region and a frame region located on at least one side of the display region; a transistor, located on the base substrate, wherein the transistor is located in the display region and includes a gate, a first electrode and an active layer; and a protective structure, located on the base substrate, wherein the protective structure is provided in the frame region and close to the display region, and the protective structure is in the same layer as and is made of the same material as at least one of the active layer, the gate or the first electrode.