Method System and Apparatus for Constructing a Customized Display Panel

• US 20190235337A1
• Filed: 02/01/2019
• Published: 08/01/2019
• Est. Priority Date: 02/01/2018
• Status: Active Grant

• Current Assignee: Richard Mccartney
• Original Assignee: Richard Mccartney
• Inventors: McCartney, Richard
• Granted Patent: US 10,747,078 B2
• Time in Patent Office: Days
• CPC Class Codes: G02F 1/1333 Constructional arrangements; Manufacturing methodsG02F1/135, G02F1/136 take precedence
• CPC Class Codes: G02F 1/133351 Manufacturing of individual cells out of a plurality of cells, e.g. by dicing
• CPC Class Codes: G02F 1/13336 Combining plural substrates to produce large-area displays, e.g. tiled displays
• CPC Class Codes: G02F 1/1345 Conductors connecting electrodes to cell terminals
• CPC Class Codes: G02F 1/13452 Conductors connecting driver circuitry and terminals of panels
• CPC Class Codes: G02F 1/13454 Drivers integrated on the active matrix substrate G02F1/136277 takes precedence
• CPC Class Codes: G02F 1/13458 Terminal pads
• CPC Class Codes: G02F 1/136286 Wiring, e.g. gate line, drain line
• CPC Class Codes: G02F 1/136295 Materials; Compositions; Manufacture processes
• CPC Class Codes: G02F 1/1368 in which the switching element is a three-electrode device G02F1/136277 takes precedence
• CPC Class Codes: G09G 2300/02 Composition of display devices
• CPC Class Codes: G09G 2340/04 Changes in size, position or resolution of an image
• CPC Class Codes: G09G 3/3648 using an active matrix G09G3/367 - G09G3/3696 take precedence

Abstract

The disclosed embodiments generally relate to a method, system and apparatus for forming a custom-sized display panel. An exemplary method to form a custom display from a large sheet of pixels includes: providing a sheet of pixels having a TFT substrate, a liquid crystal layer and a second substrate, the sheet of pixels having a first perimeter, the liquid crystal medium interposed between the TFT substrate and the second substrate; forming a display panel from the sheet of pixels, the display panel having a display panel perimeter, the second display having a first edge defined by the TFT substrate extending beyond the second substrate to thereby expose an electrical trace on the TFT substrate; sealing the liquid crystal layer on the first edge; conductively exposing the electrical trace on the TFT substrate; and forming a column driver line on the TFT substrate to communicate a driver signal to the second display.

Claims

1. A method to form a custom display from a sheet of pixels, the method comprising:

providing a sheet of pixels having a TFT substrate, a liquid crystal layer and a second substrate, the sheet of pixels having a first perimeter, the liquid crystal medium interposed between the TFT substrate and the second substrate;

forming a display panel from the sheet of pixels, the display panel having a display panel perimeter, the second display having a first edge defined by the TFT substrate extending beyond the second substrate to thereby expose an electrical trace on the TFT substrate;

sealing the liquid crystal layer on the first edge;

conductively exposing the electrical trace on the TFT substrate; and

forming a column driver line on the TFT substrate to communicate a driver signal to the second display.

2. The method of claim 1, further comprising connecting the column driver line on the TFT substrate to an external driver.

3. The method of claim 2, wherein connecting the column driver line on the TFT substrate further includes wire-bonding a driver line to the at least one etched electrical trace.

4. The method of claim 1, wherein the external driver further comprises a scalar to convert an incoming image signal from

5. The method of claim 1, wherein conductively exposing the electrical trace further comprises exposing the electrical trace by substantially removing a passivation layer.

6. The method of claim 1, wherein conductively exposing the electrical trace further comprises removing SiO2 from the electrical trace.

7. The method of claim 1, wherein the TFT substrate extends beyond the second substrate by about 0.5 to 3 mm.

8. The method of claim 1, wherein forming a column driver line on the TFT substrate further comprise laser ablating to define a conductive path on the TFT substrate.

9. The method of claim 8, further comprising connecting the conductive path with an external column driver and wherein the column driver is configured to scale a first image signal configured for the display panel to a second image signal configured to be displayed on the display panel.

10. The method of claim 1, wherein the display panel comprises a first edge positioned at an angle with respect to at least one other edge of the display panel.

11. The method of claim 1, wherein the second substrate is a color filter substrate.

12. The method of claim 1, wherein the second perimeter is smaller than the first perimeter.

13. A method to convert a pixel of a first display panel to a driver-contact point, the method comprising:

uncovering a first pixel of a plurality of pixels on a surface of a display panel, the pixel having a plurality of tracelines including a row traceline and a column traceline to engage the first pixel;

electrically exposing the row traceline and the column traceline of the first pixel to thereby form an exposed row traceline and an exposed column traceline;

connecting a row driver line to the exposed row traceline; and

connecting a column driver line to the exposed column traceline.

14. The method of claim 13, wherein uncovering a first pixel on a surface of a display panel further comprises removing one or more display panel layers to uncover a plurality of electrical tracelines on a substrate surface of the display panel.

15. The method of claim 13, wherein electrically exposing the row traceline further comprises etching the row traceline to remove an insulating layer.

16. The method of claim 13, wherein electrically exposing the row traceline further comprises physically removing an insulating layer covering the row traceline.

17. The method of claim 13, further comprising substantially isolating the column traceline from a first adjacent column traceline.

18. The method of claim 17, wherein substantially isolating the column traceline further comprises forming an opening to isolate the column traceline from the first adjacent column traceline.

19. The method of claim 13, wherein the column driver line comprises communicates with a flex driver line.

20. The method of claim 14, wherein uncovering a first pixel further comprises cutting a display panel from a sheet of pixels to form the display panel, the display panel having a perimeter.

21. The method of claim 20, wherein at least one side of the display panel is at an acute angle with respect to at last one other side of the display panel.

22. The method of claim 13, wherein the display panel defines a backlit display panel.

23. The method of claim 20, wherein the display parameter is smaller than a perimeter of the sheet of pixels.