Metal Layer Segmentation for Laser Repair in Display Devices

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Solution Overview

Problem

In display devices, especially in smartphones, the presence of sensor devices on the front surface can overlap with the display panel, causing defective pixels to be affected and preventing effective lighting inspection due to metal layers blocking laser beams used for repairing active wiring.

Innovation Solution

A display device design where a hole is defined through the metal layer on the rear surface of a pixel portion, allowing a specific wavelength laser to be emitted for inversion repair, thereby preventing lighting of defective pixels by opening the active wiring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a metal layer is disposed on the rear surface of the pixel portion to block light transmission, then the sensor devices can be protected from direct light exposure, but the laser beam for removing defective active wiring cannot penetrate through the metal layer

Engineering Contradiction:

Improvelight exposure to sensor devicesVSAvoidlaser beam penetration for active wiring removal

Core Design Contradiction:

Object-affected harmful factorsVSEase of repair

Solution Approach 1:

The metal layer is segmented by forming holes at specific positions, dividing the continuous metal layer into multiple sections. This allows the laser beam to pass through the holes to reach and remove defective active wiring, while the remaining metal layer portions continue to block light from reaching sensor devices.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metal layer is designed with different local properties: regions with holes allow laser penetration for repair operations, while regions without holes maintain light blocking functionality. This spatial variation in local quality enables simultaneous achievement of both repair accessibility and sensor protection.

Inventive Principle:

Principle #3Local quality

2Ease of repair

If holes are defined through the metal layer to allow laser beam penetration, then defective pixels can be repaired by removing active wiring, but the metal layer's light blocking capability is reduced

Engineering Contradiction:

Improveaccessibility for laser beam to remove active wiringVSAvoidlight transmission to sensor devices

Core Design Contradiction:

Ease of repairVSObject-affected harmful factors

Solution Approach 1:

The metal layer is divided into multiple segments by creating holes at specific locations. This segmentation allows selective laser beam access to defective pixels while preserving the light blocking function in non-hole regions, resolving the contradiction between repair accessibility and sensor protection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The holes in the metal layer act as intermediaries that allow the laser beam to pass through to reach the active wiring for removal, while the surrounding metal layer material continues to serve as the light blocking barrier, mediating between the conflicting requirements of laser penetration and light blocking.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Area of stationary object

If sensor devices are disposed to overlap the display panel to widen the display area, then the display device can achieve full-screen display effect, but defective pixels overlapping sensor devices cannot be effectively inspected and repaired

Engineering Contradiction:

Improvedisplay areaVSAvoiddefective pixel inspection and repair

Core Design Contradiction:

Area of stationary objectVSEase of repair

Solution Approach 1:

The metal layer is segmented with holes positioned to provide laser access to defective pixels that overlap sensor devices. This segmentation enables repair operations on previously inaccessible pixels while maintaining the overlapping configuration for full-screen display effect.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The problem is solved by utilizing the thickness dimension of the display panel structure. Holes are formed through the metal layer in the thickness direction, creating vertical laser beam pathways that bypass the horizontal overlap between sensor devices and pixel portions, enabling access to previously blocked defective pixels.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 design enhances the reliability and image quality by enabling effective repair of defective pixels without interfering with sensor devices, allowing for improved display performance and maintenance.

Implementation Method 1

a laser of a specific wavelength is emitted thereto through the hole

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS11581392B2Display device

Publication Date: 2023.02.14 SAMSUNG DISPLAY CO LTD

AI summary

A display device includes a display panel including a first display area including first pixels, and a second display area including a pixel portion, in which second pixels are disposed, and a transmission portion through which light is transmitted. The pixel portion of the second display area includes a base member, a metal layer disposed on the base member to define the transmission portion, a first active layer disposed on the metal layer and including a first material, and a first gate layer disposed on the first active layer. A hole is defined through the metal layer to overlap at least a part of the first active layer in a thickness direction.