Array Substrate Barrier Stack for Water and Oxygen Blocking

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Solution Overview

Problem

Current thin-film transistor layers in display panels have a poor ability to block water and oxygen, leading to damage and reduced yield due to simple packaging structures.

Innovation Solution

An array substrate is developed with a thin-film transistor layer covered by an insulating nanoparticle layer and an organic polymer layer, where a chemical bond is formed between the insulating nanoparticle layer and the organic polymer layer, and an inorganic layer is added to enhance protection, using SiO2 nanoparticles and a polystyrene derivative to create a compact, stable packaging structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a simple inorganic layer packaging structure is used, then the device complexity is reduced and manufacturing is easier, but the ability to block water and oxygen deteriorates

Engineering Contradiction:
Improvepackaging structure manufacturingVSAvoidwater and oxygen blocking ability
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent applies composite materials by combining inorganic nanoparticle layers (such as Al2O3, SiO2, TiO2, or ZnO nanoparticles) with organic polymer layers (such as polyimide, polycarbonate, or polymethyl methacrylate) to form a multi-layer packaging structure. This composite structure leverages the advantages of both inorganic materials (excellent water and oxygen barrier properties) and organic materials (flexibility and ease of processing), thereby resolving the contradiction between manufacturing simplicity and blocking performance. The inorganic nanoparticle layer provides superior water and oxygen blocking capability, while the organic polymer layer ensures structural integrity and ease of manufacture.

Inventive Principle:
Principle #40Composite materials

2Reliability

If a multi-layer packaging structure with insulating nanoparticle layer and organic polymer layer is used, then the water and oxygen blocking ability is improved, but the device complexity increases

Engineering Contradiction:
Improvewater and oxygen blocking abilityVSAvoidpackaging structure complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the packaging structure into distinct functional layers: an inorganic nanoparticle layer for water and oxygen blocking, and an organic polymer layer for structural support and protection. This segmentation allows each layer to be optimized for its specific function, with the inorganic layer providing superior barrier properties and the organic layer providing mechanical strength and flexibility. The layered structure resolves the contradiction by organizing complexity into manageable, functionally-specific segments rather than using a single monolithic structure.

Inventive Principle:
Principle #1Segmentation

3Stability of the object's composition

If chemical bonds are formed between the insulating nanoparticle layer and the organic polymer layer, then the stability of the packaging structure is improved, but the manufacturing precision requirements increase

Engineering Contradiction:
Improvepackaging structure stabilityVSAvoidbonding interface precision
Core Design Contradiction:
Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by modifying the chemical parameters of the nanoparticle surfaces through surface treatment or functionalization. This treatment introduces reactive groups on the nanoparticle surfaces that can form chemical bonds with the organic polymer layer, thereby enhancing interfacial adhesion and overall structure stability. By changing the surface chemistry parameters of the nanoparticles, the patent achieves strong bonding without requiring extremely high manufacturing precision, as the chemical affinity naturally guides the bonding process.

Inventive Principle:
Principle #35Parameter changes

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 increases the compactness of the array substrate, significantly blocking water and oxygen intrusion, thereby extending the lifespan of the display panel.

Implementation Method 1

a chemical bond is formed between the insulating nanoparticle layer and the organic polymer layer

Methodology Applied
Scientific EffectChemical bonding: Chemical Bonding

Implementation Method 2

A hydrogen bond is formed between the carboxyl structure and the oxide nanoparticle

Methodology Applied
Scientific EffectHydrogen bonding: Chemical Bonding

Implementation Method 3

A SiO2 nanoparticle in the insulating nanoparticle layer and a SiO2 nanoparticle in the inorganic layer form a silicon-oxygen bond

Methodology Applied
Scientific EffectSilicon-oxygen bonding: Chemical Bonding

Data Source

PatentUS11869901B2Display panel, array substrate, and manufacturing method thereof
Publication Date: 2024.01.09 SHENZHEN CHINA STAR OPTOELECTRONICS SEMICON DISPLAY TECH CO LTD
  • US11869901B2 patent drawing
  • US11869901B2 patent drawing

AI summary

The present application discloses a display panel, an array substrate, and a manufacturing method thereof. The array substrate includes a substrate, a thin-film transistor layer, an insulating nanoparticle layer, and an organic polymer layer. The thin-film transistor layer is disposed on the substrate. The insulating nanoparticle layer is disposed on the substrate and covers the thin-film transistor layer. The organic polymer layer is stacked on a side of the insulating nanoparticle layer away from the thin-film transistor layer and covers the insulating nanoparticle layer.