Pad Part Structure for Display Device Electrical Connection
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Solution Overview
Problem
Existing display device manufacturing processes are inefficient due to complex and time-consuming methods for connecting lead electrodes and connection lines, which result in increased manufacturing time and costs.
Innovation Solution
A display device is designed where a pad part is formed by filling a micro hole with conductive ink, allowing easy connection between a lead electrode below the substrate and a connection line above the substrate, thereby simplifying the manufacturing process and reducing non-display area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to connect lead electrodes and connection lines, then electrical connectivity is achieved, but manufacturing time and complexity increase
Solution Approach 1:
The pad part structure merges multiple functions into a single component: it serves as both an electrical connection interface between the lead electrode and connection line, and as a mechanical support element. This consolidation eliminates the need for separate connection structures, thereby reducing manufacturing steps and time while maintaining electrical connectivity.
Solution Approach 2:
The pad part extends in the thickness direction (vertical dimension) to bridge the gap between the lead electrode below the substrate and the connection line above the substrate. By utilizing the vertical dimension, the connection is achieved without increasing the horizontal footprint, thereby reducing non-display area while simplifying the manufacturing process.
2Reliability
If pad part structure is added to connect lead electrode and connection line, then electrical connectivity is improved, but non-display area increases
Solution Approach 1:
The pad part utilizes the vertical dimension (thickness direction) to achieve electrical connection, extending from the lead electrode below the substrate through the substrate to the connection line above. This vertical extension allows the connection structure to occupy minimal horizontal space, thereby maintaining small non-display area while ensuring reliable electrical connectivity.
Solution Approach 2:
The pad part is nested within the contact hole structure, with the pin part of the lead electrode penetrating through the pad part. This nested arrangement allows the connection components to be housed within the existing contact hole geometry, minimizing additional area occupation while maintaining electrical connectivity between the lead electrode and connection line.
3Reliability
If pin part protrudes from lead electrode to penetrate pad part, then connection reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The pad part structure is designed with a contact hole that accommodates the pin part with some tolerance, and the lower surface of the pad part is positioned to make contact with or be spaced from the upper surface of the lead electrode. This design provides a cushioning effect that accommodates minor positioning variations during manufacturing, ensuring reliable connection without requiring extremely tight positioning tolerances.
Solution Approach 2:
The design allows for variability in the spacing between the lower surface of the pad part and the upper surface of the lead electrode, as indicated by the phrase 'may be spaced apart from'. This parameter flexibility enables the connection to maintain reliability across different manufacturing tolerances, reducing the stringency of precision requirements while still ensuring effective electrical connectivity.
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 proposed solution reduces manufacturing time and costs by minimizing the non-display area and simplifying the manufacturing process, while ensuring effective electrical connectivity between components.
Implementation Method 1
filling a micro hole with conductive ink to form the pad part
Data Source
AI summary
A display device includes a plate including an open part, a lower film disposed on the plate, a first substrate disposed on the lower film, a first connection line disposed on the first substrate, a pad part inserted into a first contact hole penetrating through the first connection line, the first substrate, and the lower film, where the pad part is connected to the first connection line, and a flexible film including a first lead electrode inserted into the open part of the plate. The first lead electrode includes a pin part protruding from an upper surface of the first lead electrode and penetrating through the pad part.