Display Device Corner Dam and Encapsulation Thickness Control
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Solution Overview
Problem
Conventional display devices with flat surfaces have limitations in increasing the screen-to-body ratio, which affects their design and consumer appeal, and existing curved surface displays face challenges in manufacturing and reliability due to issues with the encapsulation layer thickness and dam structures.
Innovation Solution
A display device with a substrate featuring a front area with a flat surface and a corner area with a multi-curved surface, utilizing a main dam and corner dams to define stripe areas, and an encapsulation layer with a thinner organic layer in the corner area, along with a spacer to maintain structural integrity and control the flow of organic materials, ensuring improved visibility and manufacturing capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If the edge of the display device is formed with a curved surface to increase the screen-to-body ratio, then the screen-to-body ratio is improved, but the encapsulation layer thickness becomes non-uniform causing manufacturing reliability issues
Solution Approach 1:
The patent applies different encapsulation layer thicknesses to different regions of the display device. Specifically, the first encapsulation layer has a first thickness in the first area and a second thickness in the second area, where the thicknesses differ. This local differentiation allows the curved surface design to maintain proper encapsulation thickness in each region, solving the manufacturing reliability issue while preserving the increased screen-to-body ratio.
2Area of moving object
If a curved surface is formed in the corner area while maintaining a flat front area, then the screen-to-body ratio is increased, but a visible boundary is created between flat and curved surfaces affecting visibility
Solution Approach 1:
The patent implements different surface geometries for different areas: the front area maintains a flat surface while the corner area features a curved surface. This local differentiation allows the display to achieve an increased screen-to-body ratio through the curved corners while keeping the main viewing area flat for optimal visibility and minimal boundary perception.
3Reliability
If the organic layer thickness is reduced in the corner area, then manufacturing reliability is improved, but the encapsulation layer may not provide sufficient protection
Solution Approach 1:
The patent employs a multi-layer encapsulation structure where the first encapsulation layer has varying thickness (first thickness in the first area, second thickness in the second area) and is combined with a second encapsulation layer. This localized thickness adjustment in specific areas allows the device to achieve manufacturing reliability by preventing defects in critical regions while the combined multi-layer structure ensures adequate protection is maintained across the entire display device.
Data Source
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AI summary
A display device includes: a substrate including a display area, the display area including a front area and a corner area disposed at a corner of the display area; a main dam disposed between the front area and the corner area; and a plurality of corner dams disposed in the corner area. The corner area may include a plurality of stripe areas defined by the plurality of corner dams. The plurality of corner dams extend from the main dam and is disposed along an edge of the plurality of stripe areas.