Tiled Display Module Interconnect to Eliminate Visible Seams
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Solution Overview
Problem
Large-sized display devices face increased defect rates and reduced productivity due to the higher number of pixels, and tiled display devices have a noticeable seam between connected display devices, reducing image immersion.
Innovation Solution
A display device and tiled display device configuration that includes a display layer with thin-film transistors, a connection line, a barrier layer, a lead line, a pad part, and a lower film, which eliminates the need for a separate polyimide substrate and reduces the defect rate of the lower film, thereby improving image immersion.
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 small display modules that are tiled together to form a large display area. Each module contains a manageable number of pixels, maintaining low defect rates while achieving a large overall display area through the arrangement of multiple modules.
Solution Approach 2:
Multiple display modules are nested or arranged in a tiled configuration where each module is a complete functional unit containing pixels, thin-film transistors, and connection lines. The modules are connected through connection lines that extend across module boundaries, creating a larger display area while maintaining the reliability of individual module fabrication.
2Area of stationary object
If multiple display devices are connected to form a tiled display, then the display area is improved, but a visible seam or boundary part appears reducing image immersion
Solution Approach 1:
Adjacent display modules are connected through shared connection lines and common structural elements (lower film, barrier layer) that extend continuously across module boundaries. This merging of structural elements eliminates visible seams and boundaries, creating a unified display surface that maintains image immersion across the entire tiled display area.
Solution Approach 2:
The lower film and barrier layer serve multiple functions: they provide structural support for individual modules, enable electrical connections between modules through continuous layers, and create a unified visual appearance across module boundaries. This multi-functionality allows the same structural elements to both divide modules for manufacturing purposes and merge them for visual purposes.
3Stability of the object's composition
If a separate polyimide substrate is used to support the display layer, then the structural stability is improved, but the manufacturing complexity increases and defect rate of supporting films increases
Solution Approach 1:
The lower film and barrier layer are combined into a single integrated structural element that replaces the traditional separate polyimide substrate. This merged structure provides the necessary structural support, electrical connection pathways, and protective functions, eliminating the need for a separate polyimide substrate and reducing manufacturing steps and associated defect rates.
Solution Approach 2:
The lower film and barrier layer structure performs multiple functions that traditionally required separate components: structural support, electrical insulation, electrical connection pathways through contact holes, and protection of the display layer. This multi-functionality reduces the number of separate components needed, simplifying manufacturing while maintaining structural stability.
Data Source
AI summary
A display device includes a display layer comprising pixels, each of the pixels having at least one thin-film transistor, a connection line electrically connected to the at least one thin-film transistor, the connection line being exposed on a lower surface of the display layer through a first contact hole formed in the display layer, a barrier layer disposed on the lower surface of the display layer and including a second contact hole connected to the first contact hole, a lead line disposed on a lower surface of the barrier layer and electrically connected to the connection line through the second contact hole, a pad part disposed on the lower surface of the barrier layer and electrically connected to the lead line, and a lower film overlapping the lower surface of the barrier layer and the lead line.