Display Wiring Stack With Vanadium-Aluminum Detour Path
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Solution Overview
Problem
The manufacturing process of display devices, particularly during laser curing, often results in electrical defects due to the loss of wirings caused by high temperatures, which can damage metal materials with low melting points like aluminum used in conductive layers.
Innovation Solution
The implementation of a multi-layer conductive structure with a base layer of vanadium (V) and a middle layer of aluminum (Al) or its alloy, where the second metal layer has a higher thickness than the first and third metal layers, and includes a void due to partial removal of the second metal layer, forming a detour path to prevent wiring disconnections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum is used in the conductive layer, then electrical conductivity is improved, but wiring loss occurs during laser curing due to low melting point
Solution Approach 1:
The conductive layer uses a composite structure with multiple metal layers including aluminum alloy as the main conductive layer and other metal layers with different properties. This composite structure combines the high conductivity of aluminum with the thermal stability of other metals, preventing wiring loss during laser curing while maintaining electrical conductivity.
Solution Approach 2:
The invention changes the material parameters by selecting specific metal layers with appropriate melting points and conductivity characteristics. The aluminum alloy layer is designed with controlled thickness and composition to balance conductivity and thermal resistance, preventing melting during laser curing process.
2Reliability
If metal layer thickness is increased to prevent wiring loss, then wiring integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The conductive layer is segmented into multiple thin metal layers instead of using a single thick layer. Each layer has a specific function and thickness, with the aluminum alloy layer being the thickest for conductivity but still relatively thin to control manufacturing complexity. This segmentation allows better control over thermal and electrical properties.
Solution Approach 2:
Different metal layers are assigned different thicknesses based on their specific functions. The aluminum alloy layer has the greatest thickness for optimal conductivity, while other layers have smaller thicknesses tailored to their specific roles in preventing wiring loss and maintaining structural integrity.
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
This configuration minimizes wiring defects by maintaining electrical conductivity and resistance even when the second metal layer melts during laser curing, ensuring the display device's reliability and performance.
Implementation Method 1
a first metal layer including vanadium (V), a second metal layer on the first metal layer and including aluminum (Al) or an Al alloy
Implementation Method 2
the second metal layer has a higher thickness than the first and third metal layers, and includes a void due to partial removal of the second metal layer
Data Source
AI summary
A display device is provided. The display device includes a substrate including a display area and a pad area, which is disposed on one side of the display area, a plurality of conductive layers disposed on the substrate, in the display area and the pad area, a passivation layer disposed on the conductive layers, and a plurality of light-emitting elements disposed on the passivation layer, in the display area, and spaced apart from one another, wherein at least one of the conductive layers includes a first metal layer, a second metal layer, which is disposed on the first metal layer, and a third metal layer, which is disposed on the second metal layer, the first metal layer includes vanadium (V), the second metal layer includes aluminum (Al) or an Al alloy, and the third metal layer includes V or titanium (Ti).