Display Panel Vernier Alignment for Flexible Circuit Bonding

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Solution Overview

Problem

Display devices face reliability issues due to misalignment between the display panel and the flexible circuit film, which can lead to decreased performance.

Innovation Solution

The display device incorporates a display panel with pads and a panel vernier mark, along with a flexible circuit film that includes leads and a film vernier mark. The conductive adhesive connects the pads and leads, ensuring precise alignment and improved reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the display panel and flexible circuit film are physically coupled through conductive adhesive, then electrical connection is achieved, but misalignment occurs reducing reliability

Engineering Contradiction:
ImprovereliabilityVSAvoidalignment precision
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The vernier mark structure is pre-designed with extension patterns that extend beyond the pad boundaries. This preliminary configuration allows the alignment reference to be available before the actual bonding process, enabling precise alignment to be achieved during assembly without requiring post-bonding adjustments.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The vernier mark serves as an intermediary alignment reference between the display panel and flexible circuit film. By introducing this intermediate reference element with extension patterns, the direct alignment problem between pads and leads is mediated through a more robust reference structure that is less sensitive to positioning errors.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Adaptability or versatility

If pads are spaced apart in the peripheral area, then connection flexibility is improved, but alignment difficulty increases

Engineering Contradiction:
Improveconnection flexibilityVSAvoidalignment difficulty
Core Design Contradiction:
Adaptability or versatilityVSDifficulty of detecting and measuring

Solution Approach 1:

The vernier mark extension patterns extend in multiple directions (first direction parallel to first pad, second direction parallel to second pad) from the same reference point. This dimensional expansion of the alignment reference allows alignment to be verified and adjusted in multiple orientations, making the alignment process easier despite the spaced-apart configuration of pads.

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

Solution Approach 2:

The vernier mark is segmented into multiple extension patterns (first extension pattern, second extension pattern, third extension pattern) that correspond to different pads. Each extension pattern provides a dedicated alignment reference for its corresponding pad, making it easier to align each individual pad-lead pair independently while maintaining overall flexibility.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentUS20250294944A1Display device and electronic device including the same
Publication Date: 2025.09.18 SAMSUNG DISPLAY CO LTD
  • US20250294944A1 patent drawing
  • US20250294944A1 patent drawing
  • US20250294944A1 patent drawing

AI summary

A display device includes a display panel, a flexible circuit film attached on the display panel, and a conductive adhesive between the display panel and the flexible circuit film. The display panel may include a base substrate including a display area and a peripheral area, pads in the peripheral area and spaced apart from each other in a first direction, and a panel vernier mark in the peripheral area and spaced apart from the pads in the first direction. The pads may include a first pad extending in a second direction perpendicular to the first direction and a second pad extending to be inclined at a first angle with respect to the second direction. The panel vernier mark may include a first extension pattern extending in parallel to the first pad and a second extension pattern extending in parallel to the second pad.