Via Layer Depressions to Stabilize Display Passivation Films

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Solution Overview

Problem

Existing display devices face issues with the passivation film detaching undesirably, which affects the reliability and processability of the manufacturing process.

Innovation Solution

A display device design that includes a via layer with depressions on the substrate, where a passivation layer is physically contacted and attached within these depressions, preventing detachment and enhancing manufacturing processability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a passivation film is applied on a flat via layer surface, then the application process is simple, but the passivation film detaches undesirably

Engineering Contradiction:

Improvepassivation film application simplicityVSAvoidpassivation film attachment stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The via layer is designed with localized depressions at specific positions where passivation film detachment is problematic. These depressions create enhanced adhesion zones without modifying the entire via layer surface, thus maintaining manufacturing simplicity while improving attachment stability at critical locations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of modifying the passivation film application process, the invention introduces a vertical dimension feature (depressions) into the via layer surface topology. This dimensional change creates mechanical interlocking that prevents detachment while keeping the passivation film application process unchanged.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If the passivation film is made thicker to prevent detachment, then attachment stability improves, but manufacturing complexity and material usage increase

Engineering Contradiction:

Improvepassivation film attachment stabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The depressions are formed in the via layer before the passivation film is applied. This preliminary structural preparation creates built-in anchoring points that enhance attachment stability without requiring thicker films or additional manufacturing steps later in the process.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If the passivation film is made thicker to prevent detachment, then attachment stability improves, but material consumption increases

Engineering Contradiction:

Improvepassivation film attachment stabilityVSAvoidpassivation film material consumption

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The depressions create localized zones of enhanced attachment without requiring uniform thickening of the passivation film across the entire via layer. This localized approach reduces overall material consumption while maintaining attachment stability at critical detachment-prone areas.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20230402436A1Display device, method of fabricating the same, and tiled display device

Publication Date: 2023.12.14 SAMSUNG DISPLAY CO LTD

AI summary

A display device may include light emitting elements disposed on a first surface of a substrate, a connection electrode disposed on a second surface of the substrate, and a via layer disposed on the connection electrode, and including at least one depression. The passivation layer may be disposed in the depression of the via layer.