Display Device Inorganic Layer Crack Prevention
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Solution Overview
Problem
Display devices with inorganic layers are prone to cracking and peeling due to external stress during manufacturing, which can propagate and damage internal circuits, especially as bezel sizes decrease.
Innovation Solution
Incorporating openings in the buffer layer with protruding portions made of organic material that contact the substrate, and a passivation layer with stacked inorganic and organic material layers to reduce stress and improve adhesion, thereby preventing crack propagation and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the bezel size is reduced, then the display area is increased, but the inorganic layer becomes more susceptible to cracking and peeling due to external stress
Solution Approach 1:
The inorganic layer is segmented by forming openings (through-holes) that divide the continuous layer into separate regions. This segmentation prevents cracks from propagating across the entire layer, as the openings act as stress relief points that interrupt crack paths while maintaining the overall structural integrity of the display device.
Solution Approach 2:
The inorganic layer is selectively removed at specific locations (peripheral regions) to form openings, creating local variations in structure. This local modification allows the inorganic layer to maintain its protective function in critical areas while reducing stress concentration at the edges where cracks typically initiate, thus preventing peeling without compromising the overall display area.
2Reliability
If the inorganic layer is made continuous to prevent peeling, then the protective function is improved, but external stress causes cracks to form and propagate
Solution Approach 1:
The openings in the inorganic layer, which might seem to weaken the protective function, actually serve as beneficial stress relief features. By intentionally creating these discontinuities, the design converts the harmful effect of stress concentration into a beneficial crack-arresting mechanism, where the openings prevent crack propagation while the remaining inorganic layer portions maintain adhesion and protection.
3Object-affected harmful factors
If openings are formed in the inorganic layer to reduce stress, then crack propagation is prevented, but the layer's protective function is compromised
Solution Approach 1:
The inorganic layer is selectively removed at specific locations (peripheral regions) to form openings, creating local variations in structure. This local modification allows the inorganic layer to maintain its protective function in critical areas while reducing stress concentration at the edges where cracks typically initiate, thus preventing peeling without compromising the overall display area.
Data Source
AI summary
A display device includes: a substrate having: a display area; and a non-display area surrounding the display area; an inorganic layer disposed in the display area and the non-display area, the inorganic layer including openings exposing the substrate; a protruding portion disposed overlapping the openings, the protruding portion contacting the substrate exposed by the openings and including an organic material; and a passivation layer disposed on the inorganic layer, the passivation layer contacting the protruding portion. Such as structure is capable of minimizing or reducing the formation of cracks and preventing or reducing formed cracks from being propagated to the inside of the display device.