Tiled Display Pad Structure With Laser Absorption for Seam Reduction
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Solution Overview
Problem
Large display devices face increased defect rates and reduced productivity due to the number of pixels, and tiled display devices suffer from visible seams that diminish immersion.
Innovation Solution
A display device design featuring a first substrate with a laser absorption layer and barrier insulating layers to prevent damage during etching, along with a flexible film connection to pad portions, minimizing non-display areas and seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a large size display device is manufactured, then the screen size is increased, but the defect rate of light emitting elements increases and productivity decreases
Solution Approach 1:
The patent divides a large display device into multiple smaller display modules that are tiled together. Each module contains its own light emitting elements and can be manufactured separately with lower defect rates, then assembled into a large-scale display system.
Solution Approach 2:
The patent introduces a laser absorption layer as an intermediary component between the lower substrate and the display layers. This layer absorbs laser energy during etching processes, preventing direct damage to the upper substrate and display layers, thereby reducing defects.
2Area of stationary object
If multiple display devices are connected to form a tiled display, then a large screen is provided, but visible seams and boundary portions reduce the degree of immersion
Solution Approach 1:
The patent merges multiple display modules into a single tiled display system with minimized visible boundaries. The boundary portions are designed to be as thin as possible, and the modules are aligned to create a seamless visual experience, effectively combining multiple small displays into one large immersive screen.
3Ease of manufacture
If etching process is performed on lower substrate, then connections are formed, but upper substrate or display layer may be damaged
Solution Approach 1:
The patent introduces a laser absorption layer as an intermediary component between the lower substrate and the display layers. This layer absorbs laser energy during etching processes, preventing direct damage to the upper substrate and display layers, thereby reducing defects.
Solution Approach 2:
The laser absorption layer is prepared in advance before the etching process. It is positioned to cover areas that would be affected by laser etching, so that when etching is performed, the damage is already mitigated by the presence of this protective layer.
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
Enhances pixel reliability and immersion by preventing substrate and display layer damage, and reduces visible seams in tiled displays.
Implementation Method 1
a laser absorption layer disposed on the first substrate, the laser absorption layer including amorphous silicon
Data Source
AI summary
A display device of a tiled display includes a first substrate including an opening hole, a laser absorption layer disposed on the first substrate, including amorphous silicon, and multiple first contact holes, a first barrier insulating layer disposed on the laser absorption layer and including multiple second contact holes overlapping the first contact holes, multiple pad portions disposed on the first barrier insulating layer and partially disposed in the second contact holes, a second barrier insulating layer disposed on the first barrier insulating layer and the pad portions, a display layer disposed on the second barrier insulating layer, and a flexible film disposed under the first substrate, inserted into the opening hole, and electrically connected to the pad portions. A portion of the first barrier insulating layer is disposed in each of the first contact holes. The pad portions are electrically insulated from the laser absorption layer.