Color Filter Dam and Support Pattern for Large Display Stitch Defects

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Solution Overview

Problem

Large display devices face challenges in forming patterns across their entire surface due to the small size of masks, leading to visible stitch defects between shot regions during the division and exposure process, and issues with sealant overflow and panel alignment.

Innovation Solution

A display device design incorporating color filter dams and support patterns to prevent sealant overflow and panel drooping, along with a photomask system that allows for different pattern widths and non-display areas to minimize the number of exposure shots and prevent stitch defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If a division and exposure process is used to form patterns on large display devices, then the mask size limitation is overcome, but visible stitch defects appear between shot regions

Engineering Contradiction:

Improvedisplay device areaVSAvoidpattern continuity

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The display device is divided into multiple shot regions that are exposed sequentially using division and exposure process. The color filter dam structure segments the non-display area to prevent sealant overflow during this multi-shot process, enabling large area coverage while maintaining pattern quality through controlled exposure zones

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The color filter dam acts as an intermediary barrier structure between the display area and non-display area. This dam prevents sealant from overflowing into the display area during the division and exposure process, thereby preventing stitch defects and maintaining manufacturing precision across large display surfaces

Inventive Principle:

Principle #24Intermediary (Mediator)

2Area of stationary object

If the number of exposure shots is increased to cover the entire display device, then complete pattern formation is achieved, but manufacturing time and complexity increase

Engineering Contradiction:

Improvedisplay device areaVSAvoidmanufacturing time

Core Design Contradiction:

Area of stationary objectVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The color filter dam is formed in advance during the manufacturing process to prevent sealant overflow before the final exposure steps. This preliminary structure preparation enables efficient multi-shot exposure without requiring additional corrective steps, reducing overall manufacturing time

Inventive Principle:

Principle #10Preliminary action

3Reliability

If sealant is applied to surround the display area, then sealing and protection are improved, but sealant overflow defects occur

Engineering Contradiction:

Improvesealing performanceVSAvoidsealant containment

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The color filter dam functions as a thin film-like barrier structure that flexibly surrounds the display area. This thin barrier prevents sealant overflow while maintaining the sealing performance and protecting the display area during manufacturing processes

Inventive Principle:

Principle #30Flexible shells and thin films

4Device complexity

If the upper panel is supported without additional structures, then device complexity is reduced, but panel drooping and short-circuit defects occur

Engineering Contradiction:

Improvesupport structureVSAvoidpanel alignment

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The support pattern is merged with the color filter dam structure, combining the sealing function and structural support function into a single integrated component. This merging prevents panel drooping and short-circuit defects while avoiding the need for separate support structures, thus maintaining device simplicity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The color filter dam structure serves multiple functions: it prevents sealant overflow, provides structural support to prevent panel drooping, and acts as a barrier to prevent short-circuit defects. This multi-functionality eliminates the need for additional separate support structures

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11215866B2Display device, photomask for color filter, and manufacturing method of display device

Publication Date: 2022.01.04 SAMSUNG DISPLAY CO LTD

AI summary

A display device includes: a first substrate including a display area and a non-display area including a first non-display area and a second non-display area on respective sides of the display area with respect to a first direction; a color filter in the display area and including a first color filter, a second color filter, and a third color filter; and a color filter dam in the non-display area, wherein the color filter dam includes a first color filter dam in the first non-display area and a second color filter dam in the second non-display area, the first color filter dam includes a same material as the first color filter, and the second color filter dam includes a same material as the second color filter.