Fan-Out Line Structure for Seamless Tiled Display Connections
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Solution Overview
Problem
Large-size display devices face increased defect rates and decreased productivity due to the larger number of pixels, and tiled display devices suffer from visible seams between connected display devices, disrupting the sense of immersion.
Innovation Solution
A display device design that includes a first substrate with a contact hole, a barrier insulating layer, a fan-out line with a protruding part inserted into a contact hole, an etching electrode, a second substrate, and a flexible film connected to the protruding part, which minimizes non-display areas and prevents seam visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple display devices are connected to form a tiled display device, then the screen size can be increased, but seams become visible between the display devices disrupting the sense of immersion
Solution Approach 1:
The patent extracts and removes the non-display area (bezel) from the visible region by positioning the fan-out line and bonding area outside the display area boundary. The flexible film connects display devices in the non-display area, making the connection invisible and eliminating the seam effect that disrupts immersion.
Solution Approach 2:
The patent moves the fan-out line and bonding structure from the two-dimensional display plane to the third dimension by routing them through the thickness direction and positioning them in the non-display area. This dimensional transition allows connections to be made without creating visible seams on the display surface.
2Area of stationary object
If the fan-out line is made thinner to reduce non-display area, then the sense of immersion is enhanced, but the reliability of electrical connections deteriorates
Solution Approach 1:
The patent applies different quality requirements to different parts of the fan-out line: in the display area, the line is made thin to minimize visible non-display area and enhance immersion, while in the non-display area, the line can be thicker to ensure reliable electrical connections and mechanical strength for bonding.
Solution Approach 2:
The fan-out line is segmented into different functional regions: a thin portion in the display area for aesthetic purposes and a thicker portion in the non-display area for reliable electrical connection. This segmentation allows each segment to be optimized for its specific function without compromising the other.
3Reliability
If the thickness of the fan-out line is increased to improve connection reliability, then electrical connection is more robust, but the non-display area becomes more visible
Solution Approach 1:
The patent resolves the conflict by moving the thick fan-out line from the two-dimensional display plane to the third dimension, positioning it in the non-display area through the thickness direction. This allows the line to have sufficient thickness for reliable connections while remaining invisible from the front view of the display.
Data Source
AI summary
A display device comprises a first substrate including a first contact hole, a first barrier insulating layer disposed on the first substrate and including a second contact hole, a fan-out line disposed in a first metal layer on the first barrier insulating layer, the fan-out line including a protruding part inserted in the second contact hole to protrude from below the first barrier insulating layer, and a recessed part formed by the second contact hole, an etching electrode disposed in the recessed part of the fan-out line, a second substrate disposed on the fan-out line and the etching electrode and including a third contact hole, a display layer disposed on the second substrate, and a flexible film disposed below the first substrate and inserted in the first contact hole to be electrically connected to the protruding part of the fan-out line.