Capping Layer Openings for Gas Discharge in Display Devices
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Solution Overview
Problem
Liquid crystal display devices face defects due to gas generation during manufacturing, leading to incomplete filling of the liquid crystal layer in active areas, which affects the reliability and image quality of the display.
Innovation Solution
A display device design incorporating a capping layer with openings that overlap color filters, allowing for the discharge of gases generated during manufacturing, thereby preventing incomplete filling of the liquid crystal layer and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a capping layer is applied to cover color filters, then protection and structural integrity are improved, but gas discharge capability deteriorates
Solution Approach 1:
The capping layer is designed with openings (through-holes) that allow gas to pass through while maintaining the overall protective function of the layer. This porous structure enables the capping layer to both protect the underlying color filters and allow harmful gas to be discharged from the encapsulation structure.
Solution Approach 2:
The capping layer is segmented by creating multiple openings distributed across its structure. These segmented openings allow gas to escape at multiple locations, preventing gas accumulation while maintaining the protective coverage of the capping layer over the color filters.
2Reliability
If the encapsulation structure is sealed completely, then protection against external contaminants is improved, but liquid crystal filling completeness deteriorates
Solution Approach 1:
The openings in the capping layer are designed to allow gas discharge during the liquid crystal filling process. This preliminary consideration of gas escape paths ensures that the liquid crystal can completely fill the display panel without being trapped by gas bubbles, while the capping layer remains in place to provide protection.
Solution Approach 2:
The encapsulation structure incorporates a porous capping layer with openings that enable gas to escape during manufacturing while maintaining overall sealing. This allows the structure to be both protective and permeable to gas during the critical filling phase.
3Ease of manufacture
If color filters are disposed around pixel transistors, then manufacturing complexity is reduced, but gas generation in this area increases
Solution Approach 1:
The capping layer is designed with localized openings positioned specifically over the color filters that are disposed around the pixel transistors. This local quality approach ensures that gas discharge paths are provided exactly where gas is generated, while maintaining the protective coverage of the capping layer in other areas.
Solution Approach 2:
The color filters disposed around the pixel transistors, which generate gas as a harmful byproduct, are now covered by a capping layer with openings that convert this harmful gas generation into a manageable situation by providing dedicated escape paths for the gas, preventing it from causing defects.
Data Source
AI summary
Provided is a display device including a display panel including a pixel including a first sub-pixel and a second sub-pixel, and a capping layer. The first sub-pixel includes a first pixel transistor disposed on a first pixel circuit area, a first pixel electrode disposed on a first pixel electrode area, a first color filter disposed on the first pixel circuit area while covering the first pixel transistor, and a second color filter disposed on the first pixel electrode area and the first pixel circuit area. The capping layer covers the first color filter and the second color filter, and a first opening is defined in one area of the capping layer, which overlaps the second color filter on a plane.