Segmented Display Substrate Wiring for High-Definition Manufacturing

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Solution Overview

Problem

The manufacturing of display apparatuses with large size and high definition faces challenges such as increased manufacturing difficulty, decreased yield, and rising costs due to the complexity of multi-layer substrates used in active matrix driving methods.

Innovation Solution

A display apparatus with a base substrate featuring a digital data signal transmission system, including segmented sub-data lines and a power line on a single-layer wiring layer, integrated with a display driver circuit and light emitting diodes, and a substrate layer with polyimide material for improved signal transmission and reduced thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a multi-layer substrate is used for active matrix driving method, then the display apparatus can control a plurality of pixels with high definition, but the manufacturing difficulty increases and yield decreases

Engineering Contradiction:
Improvedisplay definitionVSAvoidmanufacturing difficulty
Core Design Contradiction:
Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent segments the substrate structure by separating the pixel array from the driving circuit. The pixel array is formed on a first substrate while the driving circuit is integrated on a second substrate, which are then bonded together. This segmentation eliminates the need for complex multi-layer wiring within a single substrate, reducing manufacturing difficulty while maintaining high display definition through the segmented architecture.

Inventive Principle:
Principle #1Segmentation

2Measurement precision

If a multi-layer substrate is used for active matrix driving method, then the display apparatus can control a plurality of pixels with high definition, but the manufacturing yield decreases

Engineering Contradiction:
Improvedisplay definitionVSAvoidmanufacturing yield
Core Design Contradiction:
Measurement precisionVSProductivity

Solution Approach 1:

By dividing the display apparatus into separate pixel array and driving circuit modules on different substrates, the patent enables independent manufacturing and testing of each module. This segmentation improves manufacturing yield by allowing defective modules to be identified and replaced without scrapping the entire display, while still achieving high definition through the integrated architecture.

Inventive Principle:
Principle #1Segmentation

3Ease of operation

If a multi-layer substrate is used for active matrix driving method, then the display apparatus can control a plurality of pixels, but the manufacturing cost increases

Engineering Contradiction:
Improvepixel control capabilityVSAvoidmanufacturing cost
Core Design Contradiction:
Ease of operationVSEase of manufacture

Solution Approach 1:

The patent merges the pixel array and driving circuit onto a single display structure through substrate bonding, eliminating the need for separate multi-layer wiring within one substrate. This merging approach reduces manufacturing cost by simplifying the substrate fabrication process while maintaining full pixel control capability through the integrated architecture.

Inventive Principle:
Principle #5Merging (Combining)

4Productivity

If segmented sub-data lines are used on a single-layer wiring layer, then the manufacturing yield improves and costs reduce, but the device complexity increases

Engineering Contradiction:
Improvemanufacturing yieldVSAvoidwiring structure complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent segments the data lines into multiple sub-data lines on a single-layer wiring layer, with each sub-data line connecting to corresponding pixel electrodes. This segmentation improves manufacturing yield by simplifying the wiring layer fabrication process while managing complexity through systematic routing patterns that distribute signals efficiently across the display array.

Inventive Principle:
Principle #1Segmentation

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 configuration enhances manufacturing yield and reduces costs by simplifying the substrate structure, improving signal transmission efficiency, and maintaining high definition and flexibility in display panels.

Implementation Method 1

a light emitting layer in which a plurality of light emitting diode (LED) devices are disposed to form a pixel

Methodology Applied
Scientific EffectLight emitting diode: Light Emitting Diode

Data Source

PatentUS11741886B2Display apparatus and method of manufacturing the same
Publication Date: 2023.08.29 SAMSUNG ELECTRONICS CO LTD
  • US11741886B2 patent drawing
  • US11741886B2 patent drawing
  • US11741886B2 patent drawing

AI summary

A display apparatus is provided. The display apparatus includes a substrate having a data line disposed thereon, a plurality of pixel modules arranged in a matrix format on the substrate, and a driver providing a digital data signal through the data line to each of the pixel modules. Each of the pixel modules may include a light emitting layer in which a plurality of light emitting diode (LED) devices form a pixel, a driving layer comprising a display driver integrated circuit (DDI) below the light emitting layer and generating a driving signal to drive the LED devices, and a substrate layer, between the driving layer and the substrate, comprising a data input pad to receive the data signal and transmit the data signal to the DDI and a data output pad to provide the data signal to another adjacent pixel module.