LED Display Module Barrier Layout to Prevent Pad Short Circuits
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Solution Overview
Problem
The existing display modules face challenges in preventing short circuits between electrode pads on TFT substrates due to conductive balls of Anisotropic Conductive Films (ACF), which can lead to electrical failures and reduced reliability.
Innovation Solution
Incorporating barriers with specific geometries and materials between electrode pads, including first, second, and third barriers with inclined or curved surfaces made of organic and inorganic materials, to isolate conductive balls and prevent short circuits, while also protecting the pads from external impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive balls of ACF are used to connect LEDs to electrode pads, then electrical connection is achieved, but short circuits between adjacent electrode pads may occur
Solution Approach 1:
The patent introduces barrier structures that segment the space between adjacent electrode pads, physically dividing the area where conductive balls are placed. This segmentation prevents conductive balls from bridging adjacent pads, thereby eliminating short circuit risks while maintaining reliable electrical connections.
Solution Approach 2:
The barrier structures serve as intermediary elements between adjacent electrode pads. These barriers act as mediators that guide and constrain the placement of conductive balls, ensuring they make contact only with their intended electrode pad and not with adjacent pads, thus preventing short circuits.
2Reliability
If barrier structures are added between electrode pads to prevent short circuits, then short circuit prevention is improved, but device complexity increases
Solution Approach 1:
The patent employs thin film barrier structures that can be deposited as continuous or patterned layers between electrode pads. These thin films provide effective barrier functionality without adding significant structural complexity or thickness to the overall device architecture.
Solution Approach 2:
The barrier structures are designed to serve multiple functions: preventing short circuits between adjacent pads, guiding conductive ball placement, and potentially serving as part of the encapsulation or protection layer. This multi-functionality reduces the need for separate components, thereby minimizing overall device complexity.
3Reliability
If barrier height is increased to effectively block conductive balls, then short circuit prevention is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent designs barrier structures with heights that exceed the minimum required to block conductive balls. This excessive action ensures that even with manufacturing variations, the barriers remain effective at preventing short circuits, thereby reducing the stringency of height control requirements.
Solution Approach 2:
The patent explores different barrier height parameters and their relationships with conductive ball size and pad spacing. By optimizing these parameters, the design achieves effective short circuit prevention while maintaining relaxed manufacturing tolerances, balancing reliability with manufacturability.
Data Source
AI summary
A display module includes a substrate; a plurality of electrode pads provided on a surface of the substrate; a plurality of first barriers provided between the plurality of electrode pads; and a plurality of light-emitting diodes, each of the plurality of light-emitting diodes including device electrodes connected to corresponding electrode pads of the plurality of electrode pads, wherein each of the plurality of first barriers is provided between a pair of adjacent electrode pads corresponding to a light-emitting diode of the plurality of light-emitting diodes.