Light-Emitting Substrate Barrier Layout for Pad Overflow Blocking

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Solution Overview

Problem

The jet printing process for manufacturing a white oil reflective layer on LED substrates results in overflow, leading to oxidation and discoloration of pads, causing abnormal tin loading and preventing normal LED operation.

Innovation Solution

A substrate design with a barrier part and insulating layer configuration that includes protruding sub-barrier parts to prevent the reflective layer from overflowing onto conductive pads, ensuring precise placement and preventing abnormal tin loading.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If jet printing process is used to manufacture white oil reflective layer, then direct contact between equipment and substrate is avoided preventing scratches, but white oil overflows to pad area causing oxidation and abnormal tin loading

Engineering Contradiction:

Improvesubstrate scratchesVSAvoidwhite oil placement precision

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The patent introduces a barrier layer as an intermediary structure between the jet printing process and the conductive pad. This barrier layer, positioned at the edge of the pad area, acts as a physical mediator that intercepts and contains the white oil reflective layer material during jet printing, preventing it from reaching and contaminating the pad area while allowing the jet printing equipment to operate without direct contact with the substrate

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent segments the substrate surface into distinct functional zones by introducing a barrier layer that divides the pad area from the reflective layer deposition area. This segmentation creates clear spatial boundaries that prevent material overflow from one zone to another, ensuring that white oil is confined to its intended region and cannot migrate to the pad area during the jet printing process

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If screen-printing process is used to manufacture white oil reflective layer, then printing precision is improved, but equipment directly contacts substrate causing scratches and metal layer short-circuit

Engineering Contradiction:

Improvewhite oil printing precisionVSAvoidsubstrate scratches and short-circuit

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The barrier layer serves as a protective intermediary that enables the use of screen-printing process without direct equipment-substrate contact at critical areas. By positioning the barrier layer at the pad edges, it allows the screen printing squeegee to apply pressure and deposit material precisely while preventing direct contact with and potential short-circuiting of the conductive pad metal layers

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12604564B2Substrate and light-emitting substrate

Publication Date: 2026.04.14 TCL CHINA STAR OPTOELECTRONICS TECHNOLOGY CO LTD

AI summary

A substrate and a light-emitting substrate are provided. The substrate includes a driving function layer, an insulating layer, and a reflective layer which are sequentially arranged on a base. The driving function layer includes a conductive pad. An opening exposing the conductive pad is defined on the insulating layer. In a direction perpendicular to the substrate, a height of a part of the insulating layer located surrounding the opening is greater than a height of the reflective layer.