Display Block Member Structure for Scratch-Resistant OLED Encapsulation
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Solution Overview
Problem
The thin film encapsulation structure in flexible OLED displays is prone to defects due to surface scratches on block members, leading to reduced useful lifetime, as masks used in the manufacturing process can scratch the upper surface of these members.
Innovation Solution
The implementation of first and second block members with varying heights, where the second block member has a greater height than the first, and an irregular upper surface, formed using a half-tone slit mask, to prevent contact with the mask and enhance the encapsulation structure's integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a mask is placed on the block member to form display structures, then the display structures can be manufactured, but the upper surface of the block member can be scratched leading to thin film encapsulation defects
Solution Approach 1:
The patent introduces a height dimension differentiation between block members. The first block member has a first height and the second block member has a second height greater than the first height. This dimensional change allows the mask to rest on the taller second block member while the shorter first block member remains exposed and scratch-free, thereby preventing encapsulation defects while still enabling mask-supported manufacturing.
2Reliability
If the block member surface is made irregular to prevent mask contact, then scratches are avoided, but the manufacturing precision may be affected
Solution Approach 1:
The patent applies local quality by creating different surface characteristics in different locations. The first block member has an irregular upper surface that prevents mask contact and scratches, while the second block member provides a stable platform for mask placement. The encapsulation layer is selectively formed only on the irregular first block member surface, ensuring precision where needed while preventing scratches through surface irregularity.
3Device complexity
If a single uniform block member is used, then the structure is simple, but it cannot prevent both mask contact scratches and ensure proper encapsulation coverage
Solution Approach 1:
The patent segments the block member structure into two distinct components: a first block member with a first height and irregular upper surface, and a second block member with a second height greater than the first height. This segmentation allows each component to fulfill a specific function - the first block member prevents scratches through its irregular surface while the second block member provides mask support - thereby achieving reliability without excessive complexity.
Data Source
AI summary
A display device and a method of manufacturing the display device are disclosed. In one aspect, the display device includes a substrate including a display region and a peripheral region. A first block member is in the peripheral region and surrounding display structures, the first block member having a first height. A second block member is spaced apart from the first block member in a first direction extending from the display region to the peripheral region, the second block member surrounding the first block member, the second block member having a second height that is greater than the first height. A first encapsulation layer is over the display structures, the first block member, and the second block member. A second encapsulation layer is over the first encapsulation layer, the second encapsulation layer overlapping at least a portion of the first block member in the depth dimension of the display device.