Display Cathode Layer Segmentation for Laser Patterning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In display apparatuses, the thermal energy distribution from laser beams used for patterning can cause defects due to uneven heat conduction, particularly affecting the cathode layer in areas with cameras or sensors.
Innovation Solution
The implementation of a display apparatus with a physical disconnected cathode layer structure, utilizing an under-cut structure to prevent edge curling and heat conduction, allowing for patterning with low thermal energy and improved reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser beam is used for patterning the cathode layer in the imaging area, then the cathode layer can be formed, but uneven thermal energy distribution causes edge curling and defects
Solution Approach 1:
The cathode layer is divided into two separate cathode layers: a first cathode layer in the light-emitting area and a second cathode layer in the light-transmitting area. This segmentation allows independent formation and optimization of each cathode layer, preventing thermal interference and edge curling that occur when a continuous cathode layer is patterned with laser beams.
Solution Approach 2:
The cathode layer in the light-transmitting area is extracted and separated from the continuous cathode structure. By removing the connecting portion of the cathode layer between the light-emitting and light-transmitting areas, the patent eliminates the source of thermal-induced edge curling while maintaining the necessary electrical functionality through alternative conductive paths.
2Reliability
If continuous cathode layer is used across light-emitting and light-transmitting areas, then electrical continuity is maintained, but thermal energy causes edge curling in the light-transmitting area
Solution Approach 1:
Different cathode layer configurations are applied to different areas: the light-emitting area has a continuous cathode layer for optimal electrical contact, while the light-transmitting area has a separated cathode layer structure that prevents thermal-induced deformation. This local differentiation resolves the conflict between electrical continuity and shape stability.
Solution Approach 2:
The cathode layer is segmented into distinct regions with different structural characteristics. The first cathode layer in the light-emitting area maintains continuity for electrical function, while the second cathode layer in the light-transmitting area is structurally separated to prevent edge curling, achieving both electrical continuity and shape stability through functional segmentation.
3Manufacturing precision
If high thermal energy is applied for patterning, then cathode layer formation is achieved, but damage occurs to the cathode layer and surrounding structures
Solution Approach 1:
By segmenting the cathode layer into separate regions, the patent enables low-thermal-energy patterning in the light-transmitting area. The separated second cathode layer can be formed with minimal thermal input, avoiding the thermal damage that would occur with high-energy laser patterning of a continuous cathode layer.
Solution Approach 2:
Instead of applying high thermal energy across the entire cathode layer structure, the patent applies partial action by limiting thermal energy input to only where necessary. The separated cathode layer structure allows patterning with low thermal energy, sufficient for the reduced area, thereby avoiding excessive thermal damage to surrounding structures.
Data Source
AI summary
The present disclosure relates to a display apparatus. The display apparatus includes a plurality of light-transmitting areas disposed between the plurality of pixels. The light-transmitting area is formed between structures disposed in the light-emitting area adjacent to the light-transmitting area, and the structure physically disconnects a cathode layer of the light-emitting area and a cathode layer of the light-transmitting area. The cathode layer may be patterned in the light-transmitting area. Accordingly, when patterning is performed with a laser, it is possible to prevent the edge of the cathode layer from being curled in the outer portion of the light-transmitting area. In addition, it is possible to pattern with low energy and solve the damage due to thermal energy of the laser beam by preventing heat conduction to the light-emitting area of the light-emitting device layer. Further, it is possible to improve the reliability by blocking the moisture permeable path.