Welding Structure for Display Module with Support Members
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Solution Overview
Problem
During the welding process of a chip on film and a screen body in display modules, cracks often occur, leading to poor display performance due to pressure-induced stress, which can extend to lines in the display module.
Innovation Solution
A welding structure comprising an output carrier with a first welding area, an input carrier with a second welding area electrically connected to the first, and support members positioned beyond the welding areas to distribute pressure and reduce the likelihood of cracking, including first and second support members on the input and output carriers respectively, which are designed to be electrically floating and made of metal for high hardness and low cracking probability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure head is used to press-fit chip on film and screen body during welding, then welding connection is achieved, but cracks occur at edges of welding area and may extend to display lines
Solution Approach 1:
Support members are pre-positioned on the chip on film and screen body at locations beyond the welding area before the welding process. These support members are designed to withstand the pressing force during welding, preventing cracks from forming or extending to the edges of the welding area and to display lines.
Solution Approach 2:
Support members act as intermediary elements between the pressure head and the edges of the welding area. These support members absorb and distribute the pressing force, protecting the fragile edge regions from direct stress while still allowing the welding connection to be formed.
2Reliability
If pressure head applies sufficient pressure for welding, then electrical connection is established, but stress concentration causes cracks at welding area edges
Solution Approach 1:
Support members are positioned in advance at locations beyond the welding area where they can intercept and distribute stress concentration before it reaches the edges of the welding area. This preliminary positioning prevents stress-induced cracks while allowing sufficient pressure to be applied for electrical connection.
Solution Approach 2:
The support members change the stress distribution parameters during welding by providing additional structural support. This modifies the stress concentration pattern, redirecting forces away from the welding area edges while maintaining the necessary pressure for electrical connection.
3Manufacturing precision
If welding pressure is increased to ensure good electrical connection, then connection quality improves, but cracking probability at edges increases
Solution Approach 1:
Support members serve as intermediary structural elements that enable higher welding pressures to be applied without compromising crack resistance. These support members mediate between the increased pressure required for good electrical connection and the need to prevent edge cracking, allowing both requirements to be satisfied simultaneously.
Solution Approach 2:
By pre-positioning support members before welding, the structure is prepared to withstand higher pressures during the welding process. This preliminary reinforcement allows increased welding pressure to be applied for better electrical connection while the support members prevent the resulting stress from causing cracks.
Data Source
AI summary
A welding structure and a display module. The welding structure includes: an output carrier, arranged with a first welding area on a side edge of the output carrier; an input carrier. A first end of the input carrier is arranged with a second welding area, the second welding area being electrically connected to the first welding area; an orthographic projection of the first end of the input carrier on the output carrier is disposed beyond the first welding area; and at least one set of a first support member and a second support member. The first support member is disposed on the input carrier and at a position of the first end beyond the first welding area; the second support member is disposed on the output carrier and opposite to the first support member.