Dam Height Differential and Encapsulation for Display Defect Prevention
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Solution Overview
Problem
Display devices with curved panels face defects due to damage from mask imprinting in the dam structures, which affects their performance and reliability.
Innovation Solution
A display device design featuring a substrate with a front portion, bending portions, and corner portions, including first and second dams with cutout patterns, where the first dam has a higher upper surface height than the second dam, and an organic encapsulation layer covers both dams, preventing damage from mask imprinting by controlling the flow of the encapsulation material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mask imprinting is used to form dam structures, then manufacturing precision is improved, but the dam structures are damaged causing defects
Solution Approach 1:
The patent applies preliminary action by forming a protective organic encapsulation layer before the mask imprinting process. This layer is prepared in advance to prevent damage to the dam structures during subsequent manufacturing steps, allowing precise mask imprinting while maintaining structural integrity.
Solution Approach 2:
The organic encapsulation layer serves as a cushioning protective layer that absorbs or distributes the mechanical stress and pressure from the mask during imprinting. This beforehand cushioning prevents direct contact between the mask and the vulnerable dam structures, eliminating the damage-defect relationship.
2Device complexity
If the first dam and second dam are at the same height, then manufacturing complexity is reduced, but encapsulation effectiveness is compromised
Solution Approach 1:
The patent applies local quality by creating different heights for different dam structures within the same device. The first dam and second dam have different upper surface heights relative to the substrate, allowing each dam to be optimized for its specific location and function. This local differentiation improves encapsulation effectiveness without requiring complex multi-layer manufacturing processes.
Data Source
AI summary
A display device includes: a display panel having a front portion, a first bending portion, a second bending portion, and a corner portion, the display panel including a plurality of first pixels disposed in the front portion and a plurality of second pixels disposed in the corner portion. The display panel includes: a substrate; a first dam surrounding the plurality of first pixels; and a second dam surrounding the plurality of second pixels. The substrate includes a plurality of cutout patterns disposed in the corner portion, the plurality of second pixels and the second dam are disposed in each of the plurality of cutout patterns, and a height of an upper surface of the first dam is higher than a height of an upper surface of the second dam, based on one surface of the substrate.