Flexible Display Terminal Groove for Yield
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Solution Overview
Problem
Existing methods for manufacturing flexible organic EL display devices face challenges in achieving high yield and efficient production, particularly in ensuring proper electrical connections and substrate separation without damaging the display device.
Innovation Solution
The manufacturing method involves a base substrate with a display region and a terminal electrically connected by an anisotropic conductive film, where the substrate is supported by a trench formed between the terminal and the side surface, allowing for separation from a supporting substrate while maintaining electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the terminal is formed close to the side surface of the substrate to maximize the display region, then the display area is increased, but the risk of damage during substrate separation increases and manufacturing yield decreases
Solution Approach 1:
The patent introduces a groove that segments the substrate structure, creating a physical separation between the terminal region and the side surface. This segmentation allows the terminal to be positioned closer to the edge while the groove provides structural support and prevents damage during separation, thus increasing display area without compromising manufacturing yield.
Solution Approach 2:
The groove acts as an intermediary structural element between the terminal and the side surface. It provides mechanical support and stress relief in the critical region, enabling the terminal to be formed closer to the edge while protecting it from damage during the substrate separation process, thereby resolving the contradiction between maximizing display area and maintaining manufacturing reliability.
2Reliability
If the anisotropic conductive film is extended close to the side surface to ensure electrical connection, then electrical connectivity is improved, but the risk of short circuit and damage during separation increases
Solution Approach 1:
The groove segments the region between the terminal and side surface, creating a physical barrier that prevents the anisotropic conductive film from extending too close to the side surface. This segmentation ensures adequate electrical connection while maintaining safe clearance to prevent short circuits and damage during separation.
Solution Approach 2:
The groove serves as an intermediary structure that controls the extension of the anisotropic conductive film. It provides the necessary electrical connection pathway while simultaneously acting as a protective barrier that prevents the conductive film from reaching positions where it could cause short circuits or damage during substrate separation.
3Device complexity
If the substrate structure is simplified to reduce manufacturing complexity, then device complexity is reduced, but the ability to protect the terminal during separation is compromised
Solution Approach 1:
The groove introduces a simple segmented structure into the substrate that provides targeted protection to the terminal region. This minimal structural addition creates effective stress relief and physical protection without significantly increasing overall device complexity, maintaining manufacturing simplicity while enhancing terminal protection capability.
Data Source
AI summary
Provided is a display device and a manufacturing method of the same. The display device includes: a base substrate having a top surface and a side surface, a display region over the top surface, a terminal over the top surface and between the display region and the side surface, the terminal being electrically connected to the display region, and an anisotropic conductive film over the terminal. An edge portion of the anisotropic conductive film is spaced from the side surface, and its distance is equal to or larger than 10 μm and equal to or smaller than 1 mm.