Display Substrate Repair Hole for Data Line Laser Access
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Solution Overview
Problem
Conventional methods for repairing electrical connection failures in LCD panel signal lines are hindered by the presence of a color filter, which covers the data line, making laser cutting and repair line connection impossible, leading to increased defects and repair challenges.
Innovation Solution
A display substrate design that includes a repair hole exposing the crossing area between the gate and data lines, allowing for electrical connection repair, and a repair electrode or line formed using the same material as the pixel electrode, enabling connection through laser chemical vapor deposition or irradiation, with a covering pattern to prevent defects from foreign materials and fill the repair hole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a color filter is disposed on the same lower substrate as the gate line and the data line, then the display quality is improved, but the data line is covered making repair impossible
Solution Approach 1:
The patent divides the organic layer into two functional regions: a color filter layer covering most of the data line, and a repair hole region where the organic layer is removed to expose the data line crossing area. This segmentation allows the color filter to maintain display quality while the exposed crossing area enables laser repair operations.
Solution Approach 2:
The patent applies different properties to different parts of the organic layer. The majority of the organic layer maintains its color filter function with full coverage, while a localized region (the repair hole) has the organic layer removed to create a repairable area. This local quality change enables repair without compromising overall display quality.
2Ease of manufacture
If a repair line is formed on the protecting layer, then the repair process is simplified, but the repair line cannot contact the data line when covered by color filter
Solution Approach 1:
The patent transitions from a two-dimensional planar repair approach (forming repair lines on the protecting layer) to a three-dimensional approach by creating a vertical opening (repair hole) through the organic layer. This dimensional change allows the repair line to make direct contact with the data line at the crossing area, establishing reliable electrical connection.
Solution Approach 2:
The repair hole acts as an intermediary structure that bridges the protecting layer and the data line. By creating this opening, the patent enables the repair line to reach and contact the data line, serving as a mediator that resolves the connection problem caused by the color filter coverage.
3Ease of repair
If the organic layer is completely removed for repair, then the data line is fully accessible, but foreign materials and height differences cause defects
Solution Approach 1:
The patent extracts only the necessary portion of the organic layer (at the crossing area) to create the repair hole, rather than removing the entire organic layer. This selective extraction provides sufficient accessibility for laser repair while minimizing the exposed area that could harbor foreign materials or create height difference defects.
Solution Approach 2:
The patent takes preliminary action to prevent harmful factors by carefully controlling the repair hole dimensions and positioning. By limiting the repair hole to the minimum necessary size for laser access, the patent preemptively reduces the risk of foreign material contamination and height difference defects before they can occur during the repair process.
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
Enables effective repair of data line defects by exposing the crossing area and using a repair electrode or line to reconnect the signal, reducing substrate defects and preventing line defects due to foreign materials and height differences.
Implementation Method 1
patterning the organic layer to form a repair hole exposing a crossing area in which the gate line crosses with the data line
Implementation Method 2
forming a repair line disposed on the crossing area and electrically connected to the data line
Data Source
AI summary
A display substrate includes a gate metal pattern comprising a gate line extending in a first direction and a gate electrode electrically connected to the gate line, a data metal pattern comprising a data line extending in a second direction crossing the first direction, a source electrode electrically connected to the data line and a drain electrode spaced apart from the source electrode, an organic layer disposed on the data metal pattern, a repair hole penetrating the organic layer and exposing a crossing area in which the gate line crosses with the data line and a pixel electrode disposed on the organic layer and electrically connected to the drain electrode.