Buffer Tank Design for Polyimide Overflow Control in Ultra-Narrow Border Displays
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Solution Overview
Problem
In ultra-narrow border LCD designs, the polyimide solution reflows and overflows due to its good fluidity, leading to sealant contamination and peeling, which complicates the manufacturing process.
Innovation Solution
A display panel design featuring a buffer tank recessed on the gate insulating layer, where the thin film encapsulation and polyimide layers fill into the buffer tank, reducing the flow rate of the polyimide solution and preventing it from overflowing, and a method involving inkjet printing and mask etching to form the buffer tank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a retaining wall is used to prevent polyimide reflowing, then the polyimide boundary control is improved, but the polyimide solution still overflows the retaining wall causing sealant contamination
Solution Approach 1:
The buffer tank acts as an intermediary structure between the display area and the sealant. It receives and contains the overflowing polyimide solution, preventing direct contact with the sealant. The buffer tank is recessed into the substrate and filled with a material that stops the polyimide flow while protecting the sealant layer.
Solution Approach 2:
The solution moves from a two-dimensional planar retaining wall to a three-dimensional buffer tank structure. By creating a recessed volume in the substrate, the system provides an additional spatial dimension to contain the polyimide solution, allowing it to be trapped before reaching the sealant level.
2Object-affected harmful factors
If the edge area is widened to accommodate retaining walls and buffer tanks, then sealant protection is improved, but the border width increases reducing ultra-narrow border design
Solution Approach 1:
The buffer tank is nested within the edge area structure, utilizing the existing space between the display area and the outer boundary. The retaining wall and buffer tank are integrated into the edge area design, maximizing space utilization without requiring additional external space.
Solution Approach 2:
The buffer tank is designed as a thin recessed structure that provides maximum protection with minimal space occupation. The tank walls are optimized to be as thin as possible while maintaining structural integrity, allowing the edge area to remain narrow.
3Ease of manufacture
If polyimide solution fluidity is maintained for good coating performance, then coating quality is improved, but the polyimide solution reflows and overflows uncontrollably
Solution Approach 1:
The buffer tank is prepared in advance on the substrate before polyimide coating. This pre-positioned structure creates a predetermined stop point that counteracts the natural reflow tendency of the polyimide solution, allowing the coating process to proceed with normal fluidity while the buffer tank prevents subsequent overflow.
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
This solution effectively prevents sealant contamination and peeling, allowing for a narrower edge area and facilitating the implementation of ultra-narrow border designs by ensuring the polyimide layer solidifies before reaching the retaining wall.
Implementation Method 1
due to the good fluidity of polyimide (PI) solution, it is not easy to control its boundary
Implementation Method 2
causing it to solidify to form the polyimide layer before flowing over the retaining wall
Data Source
AI summary
This invention provides a display panel and a fabricating method thereof. Wherein the display panel defines a display area and an edge area. The display panel includes a substrate, a gate layer, a gate insulating layer, a thin film encapsulation layer, and a polyimide layer. By disposing a buffer tank on the gate insulating layer, the flow rate of the polyimide solution printed through inkjet printing in the edge region is reduced when the polyimide layer is forming, thereby causing it to solidify to form the polyimide layer before flowing over a retaining wall, and preventing sealant contamination and peeling.