Variable-Thickness Bank Layer for Display Substrate Bonding
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Solution Overview
Problem
Display devices face challenges in preventing bonding defects between substrates, which can lead to reduced display quality and reliability, particularly in self-light-emitting display devices where precise substrate alignment and ink distribution are critical.
Innovation Solution
The implementation of a bank layer with varying thicknesses and bank grooves on the substrate, which defines openings and alternately disposed with color control patterns, helps in preventing bonding defects by managing ink distribution and maintaining the integrity of the color control pattern, thereby enhancing the bonding between substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a uniform thickness bank layer is used, then the manufacturing process is simple, but bonding defects occur between substrates
Solution Approach 1:
The bank layer is designed with different thicknesses in different regions: a first thickness in the light-emitting area and a second thickness (greater than the first) in the non-light-emitting area. This local variation in thickness provides better bonding surface area and adhesion in the non-light-emitting region, preventing bonding defects while maintaining the simplicity of the overall structure.
2Reliability
If the bank layer thickness is increased to prevent bonding defects, then bonding quality improves, but light emission is blocked
Solution Approach 1:
The bank layer thickness is locally optimized: in the light-emitting area, the thickness is kept at a first thickness that allows light to pass through effectively, while in the non-light-emitting area, the thickness is increased to a second thickness that provides sufficient bonding surface area. This spatial differentiation resolves the contradiction between light transmission and bonding quality.
3Manufacturing precision
If color control patterns are not protected, then manufacturing is easier, but pattern integrity is compromised
Solution Approach 1:
The bank layer is formed with protrusions that extend over the color control patterns before the patterns are fully processed. These protrusions act as protective barriers that prevent damage to the color control patterns during subsequent manufacturing steps, ensuring pattern integrity without adding complex protective structures.
Solution Approach 2:
The bank layer has localized thickness variations that create protective protrusions specifically positioned to cover and protect the color control patterns. This local structural modification provides mechanical protection to the patterns while maintaining the overall simplicity of the bank layer design.
Data Source
AI summary
A display device is provided. A display device including a plurality of light-output areas through which incident light is emitted and a light-blocking area which blocks the incident light, the display device includes a substrate, a bank layer which is disposed in the light-blocking area on the substrate and defines a plurality of openings, each of which is disposed in one of the plurality of light-output areas, and a color control pattern disposed in the opening of the bank layer, wherein the bank layer includes a first bank area which has a first thickness and defines the plurality of openings and a second bank area which is disposed between the plurality of openings and has a second thickness smaller than the first thickness.