Tiled Display Inspection Pad Structure for Seamless Module Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Large-sized display devices face increased defect rates and decreased productivity due to the number of pixels, and tiled display devices suffer from a sense of discontinuity between connected units, affecting image immersion.
Innovation Solution
A display device with a second barrier insulating layer, inspection pad parts, and an inspection line to quickly identify defective products and minimize non-display areas, reducing inspection time and bonding material usage, and enhancing image immersion by minimizing visible seams between units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the display device is manufactured in a large size, then the screen size increases, but the defect rate increases and productivity decreases
Solution Approach 1:
The display device is divided into multiple small display modules that are connected to form a large-sized display. Each module contains its own pixels and can be manufactured separately with lower defect rates, then assembled together to achieve the desired large screen size while maintaining high productivity through parallel manufacturing of multiple small modules
2Area of stationary object
If multiple display devices are connected to form a tiled display, then the screen size increases, but boundary portions create a sense of discontinuity
Solution Approach 1:
Adjacent display modules are connected through bonding structures that merge their boundaries, making the seams between modules imperceptible. The bonding structures include bonding pads and connection lines that are integrated into the display module design, allowing multiple modules to function as a unified continuous display surface
3Manufacturing precision
If inspection pad parts are added to identify defective products, then manufacturing precision increases, but device complexity increases
Solution Approach 1:
The display module includes self-diagnostic features through inspection pad parts and inspection lines that automatically identify manufacturing defects. These inspection elements are integrated into the module's own structure, allowing the module to self-test and self-identify defects without requiring external inspection equipment, thereby improving manufacturing precision while minimizing additional complexity
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A display device includes a first substrate including a first contact hole, a first barrier insulating layer disposed on the first substrate and including second contact holes, pad parts inserted into some contact holes of the second contact holes, inspection pad parts inserted into other contact holes of the second contact holes, fan-out lines formed of a first metal layer on the first barrier insulating layer and being integral with the pad parts, a display layer disposed on the fan-out lines, and a flexible film disposed below the first substrate and inserted into the first contact hole to be electrically connected to the pad parts. A width of each of the pad parts is greater than a width of each of the second contact holes, and a width of each of the inspection pad parts is smaller than the width of each of the second contact holes.