Display Terminal Step Minimization via Planarization Layer

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Solution Overview

Problem

In display devices, a significant step can occur between the terminal upper face and the interlayer insulating film covering the edge of the terminal, leading to poor connections between the terminal and an external circuit substrate during mounting.

Innovation Solution

A display device configuration with a TFT layer and a light emitting element layer, where the terminal includes a main portion and a peripheral portion covered by a cover film, with the terminal wiring line in contact with the peripheral portion's lower face and overlapping with the main portion via terminal base films, minimizing the step between the cover film and the terminal's exposed face.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an interlayer insulating film is used to cover the edge of the terminal, then the terminal is protected and insulated, but a significant step occurs between the terminal upper face and the interlayer insulating film upper face, causing poor connection with external circuit substrate

Engineering Contradiction:
Improveconnection reliabilityVSAvoidstep height
Core Design Contradiction:
ReliabilityVSShape

Solution Approach 1:

The patent introduces a planarization layer that extends laterally beyond the terminal edge in the horizontal dimension, filling the vertical step gap with horizontal material extension. This transforms the vertical step problem into a horizontal filling solution, where the planarization layer covers both the terminal upper face and the interlayer insulating film upper face, creating a flush surface for external circuit substrate mounting.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The planarization layer acts as an intermediary element between the terminal and the interlayer insulating film. It mediates the height difference by providing a transitional surface that connects the two structures, allowing the external circuit substrate to be mounted on a planar surface without direct contact with the stepped interface.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Ease of manufacture

If the terminal structure is simplified without additional films, then manufacturing is easier, but the step between terminal and interlayer insulating film causes poor connection during mounting

Engineering Contradiction:
Improvemanufacturing simplicityVSAvoidconnection reliability
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The planarization layer serves multiple functions simultaneously: it provides electrical insulation between the terminal and interlayer insulating film, fills the step gap to create a planar surface, and serves as an adhesive layer for mounting the external circuit substrate. This multi-functionality resolves the contradiction by adding a single element that addresses both manufacturing simplicity and connection reliability.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent changes the physical parameters of the planarization layer, including its thickness (greater than the step height), material composition (insulating material), and lateral extent (beyond terminal edge), to transform it from a simple filler into a functional component that ensures reliable connection while maintaining manufacturing feasibility.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS10777633B2Display device, display device manufacturing method, and display device manufacturing apparatus
Publication Date: 2020.09.15 SHARP KK
  • US10777633B2 patent drawing
  • US10777633B2 patent drawing
  • US10777633B2 patent drawing

AI summary

A display device includes a TFT layer provided with a terminal configured to receive a signal inputted from an external source, and a terminal wiring line in a lower layer underlying the terminal, and a light emitting element layer in an upper layer overlying the TFT layer. The terminal includes a main portion and a peripheral portion surrounding the main portion. The peripheral portion is covered by a cover film, the terminal wiring line and a lower face of the peripheral portion are in contact, and the main portion and the terminal wiring line overlap via at least one terminal base film.