Overlapping Wire Segments for Crack Detection in Display Panels
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Solution Overview
Problem
Display panels are prone to cracking in non-display areas during manufacturing, leading to inaccurate crack detection due to the ductility of single-layer detection lines, which fail to detect slight breaks and allow moisture and oxygen ingress, causing display failure.
Innovation Solution
A detection line formed by overlapping multiple wire segments with spacers in the non-display area, increasing stress at overlapping points to facilitate accurate crack detection by displaying vertical bright lines when a break occurs, and measuring resistance changes to confirm breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single-layer detection line is used in the non-display area, then the manufacturing process is simple, but the detection accuracy is low due to ductility causing slight breaks to be undetected
Solution Approach 1:
The detection line is divided into multiple wire segments (first wire segments and second wire segments) that are arranged alternately and overlap with each other. This segmentation allows the detection line to have reduced ductility at the overlapping points, enabling accurate detection of cracks while maintaining manufacturing feasibility through modular construction.
Solution Approach 2:
The detection line transitions from a single-layer structure to a multi-layer overlapping structure. The first wire segments and second wire segments are arranged in different layers with vertical overlap, creating a three-dimensional configuration that reduces ductility and enhances crack detection capability while adding structural dimensionality.
2Measurement precision
If the detection line is made more rigid to prevent ductility, then crack detection accuracy improves, but the detection line becomes more prone to breakage during manufacturing
Solution Approach 1:
By segmenting the detection line into multiple wire segments connected at overlapping points, the structure achieves localized rigidity at the overlap regions for accurate crack detection while maintaining overall flexibility and damage tolerance through the segmented architecture.
Solution Approach 2:
The overlapping structure of multiple wire segments provides built-in redundancy and stress distribution. When external forces are applied during manufacturing, the stress is distributed across multiple segments and connection points, preventing single-point failure and cushioning against manufacturing-induced breakage.
3Measurement precision
If a multi-layer overlapping detection line is used, then crack detection accuracy is enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The detection line is constructed from separate wire segments that can be manufactured and positioned independently, then assembled through overlapping. This segmentation enables modular manufacturing processes, allowing each segment to be fabricated using standard techniques and then integrated, reducing overall manufacturing complexity despite the multi-layer structure.
Solution Approach 2:
The overlapping regions of the wire segments serve as intermediary connection points that electrically and mechanically connect the segments. These intermediary overlap zones facilitate the integration of multiple layers while maintaining a relatively simple manufacturing process, as the connections are formed through natural overlap rather than requiring complex joining techniques.
Data Source
AI summary
A display panel includes a base substrate, a display area and a non-display area provided on the base substrate; a data line is provided in the display area and a detection line is provided in the non-display area on the base substrate; and the detection line is electrically connected to a data line and is formed by overlapping a plurality of wire segments. A method of manufacturing a display panel, and a display device are further disclosed.