Low-Melting-Point Bent Traces for Display Panel Self-Repair
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Solution Overview
Problem
The existing pad bending technology for display panels faces issues with low yield due to wire fractures in the bent area, which can lead to electrical signal disruption and increased production loss as the bending radius decreases.
Innovation Solution
A display panel with bent traces made from a conductive material having a melting point lower than 250°C, such as an alloy of gallium, indium, and tin, which can self-repair by melting and solidifying to reconnect broken traces, and a manufacturing method involving chemical vapor deposition, 3D printing, and atomic spray processes to form these traces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If pad bending technology is used to reduce bezel size, then the display panel achieves narrow bezel, but wire fractures occur in the bent area causing low yield
Solution Approach 1:
The patent changes the material parameter of the trace from conventional metal to low-melting-point material (melting point 100-250°C), enabling the trace to undergo phase transition under controlled heating to repair fractures without damaging other components
Solution Approach 2:
The patent utilizes the phase transition (melting and solidification) of low-melting-point material to achieve self-repair of fractured traces. When heated above the melting point, the material flows to fill gaps; when cooled, it solidifies to reconnect the trace, providing a mechanism to restore electrical connectivity after bending-induced fractures
2Area of stationary object
If bending radius is reduced to achieve narrower bezel, then bezel size decreases, but wire fracture phenomenon becomes more prominent
Solution Approach 1:
The patent implements self-service through automatic repair: when traces fracture due to bending, the low-melting-point material automatically flows to fill the gaps under localized heating and solidifies to reconnect the trace, enabling the display panel to self-repair without external intervention and thereby maintaining high process yield
Solution Approach 2:
The patent converts the harmful effect of bending-induced fractures into a beneficial self-repair mechanism. The same bending that causes fractures also activates the repair process by creating contact between fractured ends, which then fuse together when heated, transforming the defect into a restoration opportunity
3Reliability
If conventional metal trace material is used, then electrical conductivity is maintained, but fracture repair is difficult and production loss increases
Solution Approach 1:
The patent changes the material parameter from conventional metal to low-melting-point material with melting point between 100-250°C, which maintains electrical conductivity while enabling easy repair through melting and solidification processes that can be activated by controlled heating
Solution Approach 2:
The patent replaces mechanical repair methods (such as physical reconnection or welding) with a thermal-based self-repair mechanism. The low-melting-point material responds to thermal energy by flowing and filling gaps, then solidifies to reconnect traces, substituting complex mechanical repair operations with a simple thermal process
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
The self-repair capability of the display panel increases process yield and reduces production loss by effectively reconnecting broken traces without damaging other components, ensuring reliable electrical connectivity.
Implementation Method 1
the first material being a conductive material having a melting point lower than 250° C.
Implementation Method 2
a manufacturing method involving chemical vapor deposition, 3D printing, and atomic spray processes to form these traces
Data Source
AI summary
A display panel, a manufacturing method and a repair method thereof are provided. The display panel includes a flexible substrate and a plurality of bent traces. The flexible substrate includes a display portion, a bent portion, and a bezel portion being arranged in order. The bezel portion and the display portion are stacked through a bending in the bent portion. The bent portion is provided with the plurality of bent traces. Material of the bent traces includes a first material, and the first material is a conductive material having a melting point lower than 250° C. By adding the first material with the low melting point to the bent traces, when the bent traces are broken, the first material can be melted to flow by heating, thereby repairing the broken traces among the bent traces, whereby realizing the self-repair of the bent traces, increasing the process yield and reducing the production loss.