Tiled Display Pad Structure With Laser Absorption Layer Insulation
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Solution Overview
Problem
Large-sized display devices face increased defect rates and reduced productivity due to the number of pixels, and tiled display devices suffer from a visible seam between connected units, disrupting image immersion.
Innovation Solution
A display device design featuring a first substrate with a laser absorption layer made of amorphous silicon, a barrier insulating layer, pad portions, and a flexible film, which prevents damage during etching and minimizes the seam visibility by ensuring the pad portions are electrically insulated and do not directly contact the laser absorption layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a large-sized display device is manufactured with increased number of pixels, then the display area is improved, but the defect rate increases and productivity decreases
Solution Approach 1:
The display device is divided into multiple substrates (first substrate, second substrate, third substrate) that can be manufactured separately and then integrated. This segmentation allows each substrate to be produced with controlled pixel counts, reducing defect rates while achieving a large overall display area through the combination of multiple substrates.
2Area of stationary object
If a tiled display device is constructed by connecting multiple display devices, then the display area is improved, but a visible seam appears between display units reducing image immersion
Solution Approach 1:
Multiple substrates are optically integrated into a unified display structure where the first substrate, second substrate, and third substrate work together as a single optical system. The laser absorption layer and barrier insulating layers are configured to ensure optical continuity across substrate boundaries, merging the visual output to eliminate visible seams and maintain image immersion.
3Ease of manufacture
If an etching process is performed on the lower substrate, then the manufacturing process is improved, but damage may occur to the upper substrate or display layer
Solution Approach 1:
A laser absorption layer is pre-formed on the first substrate before the etching process. This layer serves as a protective measure that absorbs laser energy during etching, preventing damage to the second substrate and display layer while enabling effective etching of the first substrate.
Solution Approach 2:
The laser absorption layer acts as an intermediary between the laser etching source and the substrates. It selectively absorbs laser energy to enable precise etching of the first substrate while protecting the second substrate and display layer from laser damage, facilitating the manufacturing process without causing harm.
4Reliability
If pad portions directly contact the laser absorption layer, then electrical connection is improved, but damage may occur during laser etching process
Solution Approach 1:
A barrier insulating layer is introduced as an intermediary between the pad portions and the laser absorption layer. This barrier layer prevents direct contact while allowing the pad portions to maintain their electrical connection function, simultaneously protecting the pad portions from laser damage during the etching process.
Solution Approach 2:
The barrier insulating layer is strategically positioned only where pad portions contact the laser absorption layer, providing localized protection against laser damage while maintaining electrical connectivity in other areas. This selective application of the barrier layer optimizes both electrical connection and damage prevention.
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 defect rates and enhances image immersion by preventing seam recognition between display units, thus improving the overall display quality and user experience.
Implementation Method 1
a laser absorption layer disposed on the first substrate, the laser absorption layer including amorphous silicon
Data Source
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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.