Display Encapsulation With Contact-Curing Epoxy Stopper for Smaller Bezels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing display devices face challenges in minimizing the bezel size while maintaining effective encapsulation to prevent moisture and oxygen ingress, leading to potential deterioration of the display components and compromised image quality.
Innovation Solution
A display device design featuring a substrate with a display area and non-display area, utilizing a bank layer to define subpixels, a stopper to contain an encapsulating layer, and an encapsulating layer made of epoxy resin, with the stopper including a material that cures the epoxy resin upon contact, thereby controlling the encapsulating material flow and minimizing bezel size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the encapsulating layer is extended to prevent moisture and oxygen ingress, then the reliability is improved, but the bezel size increases
Solution Approach 1:
The patent changes the chemical state of the encapsulating material by using a curable material that transitions from liquid to solid. The material is applied in a liquid state that allows it to flow and conform to the display components, then cured to form a solid protective barrier. This parameter change enables effective encapsulation without requiring excessive material that would increase bezel size.
Solution Approach 2:
The patent introduces a stopper as an intermediary component between the encapsulating material and the bezel structure. The stopper contains the curable encapsulating material, allowing it to be precisely positioned and controlled during the encapsulation process. This intermediary enables the material to reach all necessary areas for moisture and oxygen protection while preventing overflow that would increase the bezel size.
2Manufacturing precision
If the encapsulating material is allowed to flow freely to ensure complete coverage, then the encapsulation quality is improved, but the material overflows and increases bezel size
Solution Approach 1:
The patent applies preliminary action by positioning the stopper before applying the encapsulating material. The stopper is pre-installed to define the boundaries where the material should be contained. This preliminary structuring allows the liquid encapsulating material to flow freely for complete coverage while the pre-positioned stopper prevents overflow, ensuring both encapsulation quality and controlled bezel size.
Solution Approach 2:
The stopper serves as an intermediary that mediates between the need for material flow and the need to prevent overflow. It allows the encapsulating material to flow and conform to the display components for complete coverage, while simultaneously acting as a barrier to contain the material within the desired boundaries, preventing bezel size increase.
3Reliability
If a traditional dam structure is used to contain encapsulating material, then the material overflow is prevented, but the device complexity increases
Solution Approach 1:
The patent merges the containment function with the existing stopper structure that is already part of the display device architecture. Rather than adding a separate dam structure, the stopper is integrated to serve dual purposes: its original function and the new function of containing the encapsulating material. This merging reduces device complexity while maintaining effective material containment.
Solution Approach 2:
The stopper is designed with multi-functionality, serving both its original purpose and the additional function of containing the encapsulating material. This universal component eliminates the need for separate dam structures, reducing overall device complexity while maintaining effective prevention of material 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
The solution effectively reduces bezel size and prevents encapsulating material overflow, ensuring uniform encapsulation and improved display quality by blocking moisture and oxygen ingress, thus enhancing the overall performance of the display device.
Implementation Method 1
the stopper includes a material curing the epoxy resin due to contact of the epoxy resin and the stopper
Data Source
AI summary
A display device includes: a substrate having a display area having a plurality of subpixels and a non-display area adjacent to the display area; a bank layer on the substrate to define the plurality of subpixels; a transistor and a light emitting diode in each of the plurality of subpixels; a stopper in the non-display area; and an encapsulating layer on the light emitting diode and surrounded by the stopper, wherein the encapsulating layer includes an epoxy resin, and wherein the stopper includes a material curing the epoxy resin due to contact of the epoxy resin and the stopper.