Tiled Display Device Etching Angle Optimization
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Solution Overview
Problem
Large-sized display devices face increased defect rates and reduced productivity due to the number of pixels, leading to a sense of disconnection between tiled display units, which affects the immersion and reliability of the image displayed.
Innovation Solution
A display device design that includes a first substrate with a fan-out line and a second substrate connected through a contact hole with specific etching angles, minimizing the gap between display units by using different etching processes to prevent metal layer damage and ensure reliable connection, and by positioning drivers under the substrate to minimize non-display areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If display devices are connected in a tiled configuration to achieve large screen size, then the screen area is increased, but boundary portions between display devices create a sense of disconnection and reduce immersion
Solution Approach 1:
The patent extracts and removes the non-display area (bezel) from the display device structure. By positioning the active display area to extend to the edges of the substrate and removing the traditional bezel border, the boundary between adjacent display devices becomes less visible, reducing the sense of disconnection and improving immersion in tiled configurations
Solution Approach 2:
The patent merges the display area with the substrate edges, eliminating the separation between the active display region and the substrate boundary. This merging approach allows adjacent display devices to be positioned closer together with minimal gaps, creating a more seamless visual experience in tiled arrangements
2Ease of manufacture
If contact holes are formed with standard etching angles, then manufacturing is simplified, but metal layers exposed through contact holes are damaged
Solution Approach 1:
The patent applies different etching angles to different contact holes based on their specific locations and functions. First contact holes (connecting to flexible films) use a first etching angle, while second contact holes (connecting to connection lines) use a second etching angle. This localized differentiation protects metal layers from damage while maintaining manufacturing feasibility
Solution Approach 2:
The patent changes the etching angle parameter for different contact holes to optimize both metal layer protection and manufacturing. By adjusting the etching angle as a critical parameter, the patent prevents metal layer damage that would occur with standard etching angles, while still maintaining ease of manufacture through controlled parameter variation
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 solution effectively reduces the recognition of boundary portions between display units, enhancing the sense of immersion and reliability by minimizing non-display areas and ensuring reliable connections between units.
Implementation Method 1
An etching angle of the first contact hole between a top surface of the first substrate and an inner surface of the first contact hole may be less than an etching angle of the second contact hole
Data Source
AI summary
A display device includes a first substrate including a first contact hole, fan-out lines in a first metal layer, a second substrate on the first metal layer and including a second contact hole, connection lines in a second metal layer and into the second contact hole connected to the fan-out lines, a thin film transistor in an active layer and a third metal layer on the second metal layer, and a flexible film on a surface of the first substrate and into the first contact hole connected to the fan-out lines. An etching angle of the first contact hole between a top surface of the first substrate and an inner surface of the first contact hole is less than an etching angle of the second contact hole between top surfaces of the fan-out lines and an inner surface of the second contact hole.