Tiled Display Through-Hole Alignment to Reduce Visible Seams
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Solution Overview
Problem
Large-sized display devices face increased defect rates in light emitting elements due to the number of pixels, leading to reduced productivity and reliability, and the seams between connected display devices cause a sense of disconnection, impairing immersion in the image.
Innovation Solution
A tiled display device design with precise through-hole positioning and alignment mark structures, including an insulating layer with a mask portion and alignment marks, minimizes the visibility of seams and enhances process precision, using a substrate with etching stoppers and connection lines to integrate multiple display devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple display devices are connected to form a large-sized screen, then the display size is increased, but boundary portions and non-display areas become visible creating a sense of disconnection
Solution Approach 1:
The patent extracts and removes the non-display area (bezel) from the visible boundary between connected display devices. By eliminating this harmful element through precise through-hole alignment that brings display areas directly adjacent to each other, the sense of disconnection is removed while maintaining the large screen effect.
Solution Approach 2:
The patent merges multiple display devices into a unified visual structure by eliminating visible boundaries. Through precise alignment of through-holes and removal of non-display areas, adjacent display devices are merged such that their display areas form a continuous visual field, creating the perception of a single large display.
2Measurement precision
If the number of pixels is increased to achieve large display size, then the display resolution is improved, but the defect rate of light emitting elements increases
Solution Approach 1:
The patent segments the large display into multiple smaller display devices connected through precisely aligned through-holes. This segmentation allows each individual display device to maintain a manageable pixel count and acceptable defect rate, while the overall system achieves large display dimensions through the combination of multiple units.
Solution Approach 2:
The patent employs a nested structure where multiple display devices are interconnected through through-holes that pass through substrates, etching stoppers, display layers, and insulating layers. This nested arrangement through multiple functional layers enables the integration of multiple display units while maintaining structural integrity and managing complexity.
3Manufacturing precision
If through holes are formed to penetrate multiple layers for connecting display devices, then the integration precision is improved, but the process complexity increases
Solution Approach 1:
The patent incorporates alignment mark portions protruding from corners of the mask portion before the through-hole formation process. These pre-positioned alignment marks enable precise positioning of through-holes through multiple layers (substrate, etching stopper, display layer, insulating layer) by providing reference points for alignment, thereby achieving high integration precision while managing process complexity.
Solution Approach 2:
The patent introduces alignment mark portions as intermediary elements that facilitate the complex through-hole formation process. These marks serve as mediators between the mask portion and the through-hole formation process, enabling precise alignment without requiring direct measurement or complex positioning systems, thus simplifying the overall manufacturing process.
Data Source
AI summary
A display device includes: a substrate including a display area and a non-display area, the substrate having a first portion of a through hole penetrating in a thickness direction thereof in the display area, an etching stopper on one surface of the substrate, the etching stopper having a second portion of the through hole connected to one end of the first portion of the through hole, a display layer on one surface of the etching stopper, and the display layer including a connection line on the second portion of the through hole, an insulating layer on other surface opposite to the one surface of the substrate, the insulating layer having a third portion of the through hole connected to the other end of the first portion of the through hole, and a pad unit on an other surface of the insulating layer and connected to the connection line.