Flexible Circuit Pad Width Gradient for Display Bonding Alignment

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Solution Overview

Problem

In display apparatuses, the bonding process between flexible circuit boards and display panels using anisotropic conductive films can lead to misalignment due to thermal compression, affecting electrical coupling performance.

Innovation Solution

The design incorporates a flexible circuit board with alternating substrate pads and display pads, where the width and spacing of these pads increase symmetrically away from the central axis, ensuring proper alignment and overlap areas decrease, compensated by increasing substrate pad widths, thus minimizing misalignment during thermal compression.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the bonding process uses thermal compression to bond flexible circuit board to display panel, then bonding strength is improved, but misalignment occurs between substrate pads and display pads

Engineering Contradiction:
Improvebonding strengthVSAvoidalignment precision
Core Design Contradiction:
StrengthVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating different width characteristics at different locations of the substrate pads. Specifically, the substrate pads have wider widths at their outer edges compared to their inner edges, with the width varying gradually across the pad surface. This local variation in width compensates for thermal compression-induced misalignment, ensuring that the overlap area between substrate pads and display pads remains optimal throughout the bonding process.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent implements parameter changes by modifying the width parameter of substrate pads across different regions. The width of substrate pads is designed to increase from the inner edge to the outer edge, creating a gradient width profile. This parameter variation allows the bonding structure to accommodate thermal compression effects while maintaining proper alignment and electrical coupling between the flexible circuit board and display panel.

Inventive Principle:
Principle #35Parameter changes

2Ease of manufacture

If uniform substrate pad widths are used, then manufacturing simplicity is maintained, but alignment compensation under thermal compression is insufficient

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

Solution Approach 1:

The patent applies local quality by creating different width characteristics at different locations of the substrate pads. Specifically, the substrate pads have wider widths at their outer edges compared to their inner edges, with the width varying gradually across the pad surface. This local variation in width compensates for thermal compression-induced misalignment, ensuring that the overlap area between substrate pads and display pads remains optimal throughout the bonding process.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent employs asymmetry by designing substrate pads with non-uniform width distribution. Rather than using symmetric uniform widths, the pads feature asymmetric width profiles where the outer portions are wider than the inner portions. This asymmetric design specifically addresses the asymmetric nature of thermal compression effects, providing better alignment compensation while maintaining manufacturing feasibility through standard photolithography processes.

Inventive Principle:
Principle #4Asymmetry

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 enhances electrical coupling performance by maintaining alignment and reducing overlap area discrepancies, improving the bonding process and overall display apparatus functionality.

Implementation Method 1

the bonding process between flexible circuit boards and display panels using anisotropic conductive films can lead to misalignment due to thermal compression

Methodology Applied
Scientific EffectThermal compression: Compression

Data Source

PatentUS11693458B2Display apparatus
Publication Date: 2023.07.04 SAMSUNG DISPLAY CO LTD
  • US11693458B2 patent drawing
  • US11693458B2 patent drawing
  • US11693458B2 patent drawing

AI summary

A display apparatus includes a flexible circuit board including a plurality of first substrate pads and a plurality of second substrate pads, a main circuit board connected to the flexible circuit board, and a display panel including a plurality of first display pads and a plurality of second display pads, where the plurality of first display pads is connected to the main circuit board through the flexible circuit board and each of the plurality of first display pads at least partially overlaps corresponding substrate pad of the plurality of first substrate pads, respectively, and each of the plurality of second display pads at least partially overlaps corresponding substrate pad of the plurality of second substrate pads, respectively.