Sprayed Metal Powder Conductive Layer for Display Bezel Reduction
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Solution Overview
Problem
Current display device manufacturing processes face challenges in reducing the bezel region area and minimizing process time and cost, particularly in connecting gate and data drivers to the side surfaces of the display panel.
Innovation Solution
The display device incorporates a first conductive layer formed by spraying metal powder onto pads and contact pads, with a protection layer covering the conductive layer, and an adhesive layer between the display panel and contact pads, allowing for electrical connection without direct contact with insulating layers, thereby reducing the bezel region area and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If metal powder is sprayed to form conductive layers for connecting drivers to side surfaces, then bezel region area is reduced and process complexity is lowered, but manufacturing precision and connection reliability may be compromised
Solution Approach 1:
The patent changes the physical state and application method of conductive material from traditional thick film deposition to sprayed metal powder, creating a conductive layer with optimized particle distribution and adhesion properties that maintains precision while enabling side-surface connections
Solution Approach 2:
The sprayed metal powder acts as an intermediary material between the pad and contact pad, providing a reliable conductive path that compensates for surface irregularities and ensures precise electrical connection without requiring direct contact between rigid structures
2Reliability
If complex masking and patterning processes are used to ensure connection reliability, then manufacturing precision is improved, but process time and manufacturing cost increase
Solution Approach 1:
The patent extracts and eliminates the complex masking and patterning steps from the traditional fabrication process, relying instead on the sprayed metal powder's inherent ability to form reliable conductive paths, thereby significantly reducing process time while maintaining connection reliability
Solution Approach 2:
The sprayed metal powder performs multiple functions simultaneously: it provides conductivity, self-aligns to form precise connections, and creates adhesion without requiring additional masking or patterning processes, enabling the process to serve itself without complex auxiliary steps
3Manufacturing precision
If traditional conductive layer formation methods are used with direct contact to insulating layers, then manufacturing precision is maintained, but process complexity and cost increase
Solution Approach 1:
Instead of forming conductive layers by direct deposition onto insulating layers with precise masking, the patent inverts the approach by spraying metal powder that naturally settles and adheres to form conductive paths, simplifying the process while maintaining precision through the powder's controlled application
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 approach effectively reduces the bezel region area, minimizes process time, and lowers manufacturing costs by eliminating the need for complex masking and patterning processes, while enhancing the reliability of connections and preventing issues like wire dislocation and corrosion.
Implementation Method 1
a first conductive layer on the first pad, the first conductive layer being extended to the first contact pad to electrically connect the first pad to the first contact pad
Data Source
AI summary
A display device may include a display panel including a first substrate, a second substrate on the first substrate, and a light-emitting device between the first substrate and the second substrate, an input sensing portion including a sensing electrode on the second substrate and a first pad connected to the sensing electrode, a first circuit film near a side surface of the display panel adjacent to the first pad, the first circuit film including a first contact pad spaced from the first pad, a first conductive layer on the first pad, the first conductive layer being extended to the first contact pad to electrically connect the first pad to the first contact pad, and a protection layer on the first conductive layer.