Tiled Display Interconnect Structure for Seamless Bezel Reduction
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Solution Overview
Problem
Large-sized display devices face increased defective rates of light emitting elements, reduced productivity, and decreased reliability due to the increase in pixels, leading to seams and discontinuities between tiled display devices, which affect image immersion.
Innovation Solution
A display device design featuring a substrate with a residual film and an electric conductor formed by micro-carbonizing, minimizing non-display areas by electrically connecting display drivers and connectors, and using a flexible film to reduce manufacturing costs and prevent seam visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the substrate is completely etched to form contact holes, then electrical connection is achieved, but the pad is damaged and manufacturing cost increases
Solution Approach 1:
The patent performs preliminary action by forming a residual film of the substrate before etching the contact holes. This residual film acts as a protective layer that prevents pad damage during the etching process, eliminating the need for subsequent pad protection steps and reducing manufacturing complexity while maintaining reliable electrical connection.
Solution Approach 2:
The residual film serves as an intermediary protective layer between the etching process and the pad. It mediates the interaction by absorbing the etching attack, thereby protecting the pad from damage while still allowing the etching to proceed to form the necessary contact holes for electrical connection.
2Area of stationary object
If multiple display devices are tiled to form large-sized display, then screen size is increased, but seams and boundary portions reduce image immersion
Solution Approach 1:
The patent extracts and eliminates the non-display area (bezel) from the visible region by extending the display layer into the non-display area. This extraction of the problematic boundary portion removes the source of seams and discontinuities, thereby maintaining image immersion quality while preserving the large screen area achieved through tiling.
Solution Approach 2:
The patent extends the display layer from the traditional two-dimensional display area into the third dimension of the non-display area (bezel region). This dimensional extension allows the display content to occupy the entire front surface of the device, eliminating visible seams at the boundaries between tiled display devices and enhancing image immersion.
3Reliability
If the display layer is extended into the non-display area, then seam visibility is reduced, but the structure becomes more complex
Solution Approach 1:
The patent merges the display layer with the non-display area by extending the display layer into the bezel region. This merging eliminates the visual boundary between display and non-display areas, reducing seam visibility and enhancing image immersion without requiring separate structural components for each region.
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
Prevents damage to pads during etching, reduces process time and cost, and enhances image immersion by minimizing non-display areas and seam visibility in tiled display devices.
Implementation Method 1
The electric conductor may be formed by irradiating the residual film with infrared laser beam having a femtosecond pulse to micro-carbonize the residual film.
Data Source
AI summary
A display includes a substrate including a first contact hole and a residual film of the substrate overlapping each other in a thickness direction, an electric conductor provided in the residual film and having conductivity, a first barrier insulating film disposed on the substrate and including a second contact hole, a fan-out line disposed in a first metal layer on the first barrier insulating film and including a pad disposed in the second contact hole, the pad electrically contacting the electric conductor, a display layer disposed on the fan-out line, and a flexible film disposed below the substrate, extending to the first contact hole, and electrically connected to the pad through the electric conductor.