Alternating Organic-Inorganic Sealing Layer for Flat Panel Displays
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional flat panel display devices face issues with the permeation of harmful materials like moisture and oxygen, which lead to degradation and potential loss of display function due to the ineffective prevention of these substances through the side passivation layers.
Innovation Solution
A flat panel display device with a sealing passivation layer comprising a two-layer structure of alternately deposited organic and inorganic films, integrated with bank and dummy bank portions to create a corrugated shape that contacts the substrate, effectively blocking harmful material permeation and minimizing additional processing and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-layer inorganic passivation layer is formed over the emission element, then the manufacturing process is simple, but harmful materials such as moisture and oxygen can permeate through the layer, causing degradation of the emission element
Solution Approach 1:
The patent applies composite materials by forming a multi-layer passivation structure consisting of alternating organic and inorganic films. The organic film layers (e.g., PVA, PVDC, SiOx) and inorganic film layers (e.g., SiO2, Si3N4, Al2O3) are deposited alternately to create a composite barrier that effectively blocks harmful materials like moisture and oxygen from permeating through the emission element, thereby improving reliability without excessive complexity
Solution Approach 2:
The patent segments the passivation layer into multiple thin layers with different material properties rather than using a single thick layer. The alternating organic and inorganic films are deposited in sequence, with each layer contributing different protective properties, creating a segmented barrier structure that enhances overall protection effectiveness while managing complexity through systematic layering
2Reliability
If the passivation layer is made thinner to reduce processing steps, then manufacturing complexity is reduced, but the layer becomes less effective at blocking harmful material permeation
Solution Approach 1:
The patent uses composite materials to achieve effective blocking with thin total thickness. By combining organic and inorganic films with complementary barrier properties in an alternating sequence, the multi-layer composite structure provides superior blocking effectiveness compared to a single thick layer, maintaining reliability while reducing overall thickness and processing steps
Solution Approach 2:
The patent changes the parameters of the passivation layer by using multiple thin layers with controlled thicknesses (each layer typically 50-500 nm) rather than one thick layer. The alternating deposition of organic and inorganic films with different permeation resistance characteristics creates a synergistic effect that enhances blocking effectiveness while keeping the total thickness minimal, thus easing manufacturing
3Reliability
If additional sealing structures are added to prevent side permeation, then protection effectiveness is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent applies universality by making the alternating organic-inorganic film structure serve multiple functions: it acts as both the primary passivation layer and the sealing layer. The same multi-layer structure that provides barrier protection against perpendicular permeation also seals the side surfaces of the emission element, eliminating the need for separate sealing structures and reducing manufacturing complexity and cost
Solution Approach 2:
The patent merges the passivation function and sealing function into a single integrated multi-layer structure. The alternating organic and inorganic films are deposited to cover both the top surface and side surfaces of the emission element, combining what would traditionally be separate components into one unified structure, thereby improving protection without increasing manufacturing steps
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 prevents the permeation of moisture and oxygen, thereby protecting the emission elements from degradation and maintaining the display function, while reducing additional manufacturing processes and costs.
Implementation Method 1
the permeation of harmful material such as moisture or oxygen and degradation of performance of the flat panel display device
Implementation Method 2
consisting of at least a two-layer structure including an organic film and an inorganic film alternately deposited
Data Source
AI summary
A flat panel display device including a display area in which a desired image is displayed, and a non-display area arranged outside the display area includes bank portions arranged on a substrate in a predetermined pattern in the display area and partitioning a plurality of first openings, an emission element arranged at each first opening, dummy bank portions formed in the non-display area together with the bank portions and a sealing passivation layer covering the emission element, the sealing passivation layer includes at least a two-layer structure including an organic film and an inorganic film alternately deposited, arranged along a surface defining the dummy bank portions on the upper surface of the emission element, and having a sectional portion directed to and contacting the substrate or a film on the substrate.