Tiled Display Pad Structure for Concealing Panel Seams
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Solution Overview
Problem
Large-sized display devices with light emitting elements face increased defect rates due to the number of pixels, leading to reduced productivity and reliability, and when tiled, the seams between connected display devices create a sense of disconnection, detracting from the immersion experience.
Innovation Solution
A tiled display device design featuring a substrate with a metal pattern having wet etching resistance, etching stoppers, and pad units formed through a coating process, minimizing gaps between display devices and concealing seams by integrating components like lead lines and protective films to prevent recognition of boundary areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple display devices are connected to form a large-sized display, then the display area is increased, but the seam between devices becomes visible and reduces immersion
Solution Approach 1:
The harmful non-display area (seam) is extracted and removed from the visible display region. The patent achieves this by extending the display area to overlap the non-display area, effectively taking out the seam from the visible portion and eliminating its negative impact on immersion
Solution Approach 2:
The patent transitions from a two-dimensional arrangement where seams are visible between adjacent displays to a three-dimensional overlapping configuration. By stacking display devices at an angle and allowing overlap, the seam is moved to a different spatial dimension where it is no longer visible from the front viewing angle
2Reliability
If the display area is extended to overlap the non-display area, then the seam is concealed and immersion is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent divides the display system into multiple independent display devices that can be manufactured separately using standard processes. Each device maintains its own complete structure, allowing for modular manufacturing while achieving the overlapping configuration through assembly rather than complex single-unit fabrication
Solution Approach 2:
Multiple display devices are merged in a stacked, overlapping configuration where their physical structures combine to create a unified visual display. The merging of multiple standard devices achieves the seam-concealing effect without requiring complex modifications to individual device manufacturing
3Reliability
If the display area is extended to overlap the non-display area, then the seam is concealed, but the etching precision and component alignment become more difficult
Solution Approach 1:
The patent incorporates pad units and metal patterns in the non-display area during the initial manufacturing process, before the overlapping assembly occurs. This preliminary preparation of connection structures ensures that when devices are assembled in the overlapping configuration, the electrical connections are already in place, eliminating the need for precise post-assembly alignment and etching
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 visibility of seams between display devices, enhancing the sense of immersion by maintaining the display's integrity and reliability while minimizing bezel areas, thus improving the overall viewing experience.
Implementation Method 1
a metal pattern disposed on another surface opposite to the surface of the substrate and surrounding the first contact hole in a plan view
Implementation Method 2
an etching stopper disposed on a surface of the substrate and including the first contact hole
Implementation Method 3
a first pad unit overlapping a part of the metal pattern and inserted into the first contact hole
Data Source
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AI summary
A display device includes a substrate including a first contact hole, an etching stopper disposed on a surface of the substrate and including the first contact hole, a metal pattern disposed on another surface opposite to the surface of the substrate and surrounding the first contact hole in a plan view, a first pad unit overlapping a part of the metal pattern and inserted into the first contact hole, a lead line disposed on the another surface of the substrate and electrically connected to another part of the metal pattern, a second pad unit disposed on the another surface of the substrate and electrically connected to the lead line, a protective film overlapping the another surface of the substrate and the lead line, and a protection part overlapping the first pad unit.