Tiled Display Substrate Bending Structure for Seamless Panels
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Solution Overview
Problem
Large screen display devices with multiple light-emitting elements face increased defect rates and decreased productivity due to visible seams between connected display devices, hindering viewer immersion in images.
Innovation Solution
A tiled display system with a substrate structure including a display part, a pad part, and a bending part, where the bending part has a smaller thickness than the display and pad parts, and a metal layer resistant to dry etching, which reduces bending stress and eliminates visible seams by minimizing the distance between display devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple display devices are connected to form a large screen, then the screen size is increased, but visible seams appear between devices reducing viewer immersion
Solution Approach 1:
The patent extracts and removes the bending part from the substrate structure, creating a recessed region that eliminates visible seams between connected display devices. By taking out material from the bending region, the substrate thickness is reduced at the edges, allowing adjacent displays to be positioned closer together without their edges being visible, thus solving the seam visibility problem while maintaining large screen area.
2Temperature
If a separate heat dissipation layer is added to manage thermal load, then thermal management is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The metal layer in the substrate is designed to serve multiple functions simultaneously: it provides structural support, enables bending flexibility, and acts as a heat dissipation layer. By making the metal layer multi-functional, the patent eliminates the need for separate heat dissipation layers, reducing device complexity and manufacturing steps while still achieving effective thermal management.
Solution Approach 2:
The patent merges the heat dissipation function with the structural metal layer by forming the metal layer to extend across the display area and pad area. This consolidation combines what would traditionally be separate components (structural layer and thermal management layer) into a single integrated structure, simplifying both device architecture and fabrication processes.
3Object-generated harmful factors
If the substrate thickness is uniformly reduced to eliminate seams, then seam visibility is reduced, but structural strength and reliability decrease
Solution Approach 1:
The patent applies local quality by creating a non-uniform substrate thickness profile: the bending part is removed to create a recessed region with reduced thickness at the edges, while the central display area maintains its original thickness. This localized thinning eliminates visible seams at the boundaries between connected displays while preserving the structural strength and reliability of the main display area, avoiding the need to uniformly reduce the entire substrate thickness.
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 viewer immersion by ensuring seamless image display and reducing fabrication costs and processing time through the use of a metal layer that acts as a mask for forming the bending part without a separate heat dissipation layer.
Implementation Method 1
The metal layer may comprise a metal oxide that may be resistant to dry etching. An etch rate of the metal layer may be lower than an etch rate of the substrate.
Implementation Method 2
A thermal conductivity of the metal layer may be higher than a thermal conductivity of the substrate.
Data Source
AI summary
A display device includes a substrate comprising a display part, a pad part, and a bending part between the display part and the pad part, a display layer disposed on a first surface of the display part and comprising pixels, a pad electrode disposed on a first surface of the pad part, and a metal layer disposed on a second surface of the display part and on a second surface of the pad part. The second surface of the display part is opposite to the first surface of the display part, and the second surface of the pad part is opposite to the first surface of the pad part. A thickness of the bending part is smaller than at least one of a thickness of the display part and a thickness of the pad part. A planar shape of the bending part is determined by the metal layer.