Display Edge Layer Alignment to Prevent Light Leakage
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Solution Overview
Problem
Display devices face issues with light leakage at the edges and lift-defects of the bank and optically-functional layer, particularly due to external moisture or oxygen exposure.
Innovation Solution
The display device incorporates a substrate with a display area and a non-display area, featuring a light-emitting element layer, a bank, a capping layer, overcoat layers, color filters vertically stacked in the non-display area, and an optically-functional layer. The lateral sides of these layers are aligned, and the bank is positioned closer to the display area than the substrate, reducing exposure to external elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the bank extends to the edge of the substrate, then the display area is maximized, but light leakage occurs at the edge and lift-defects occur due to moisture or oxygen exposure
Solution Approach 1:
The patent extends the protective structure into the non-display area beyond the substrate edge, using multiple stacked layers (bank, capping layer, overcoat layer, color filters, second overcoat layer) arranged vertically and horizontally to create a multi-dimensional barrier that prevents light leakage while maintaining display area maximization
Solution Approach 2:
The bank is positioned closer to the display area than the substrate edge, creating a preliminary protective barrier before the edge is reached. This preliminary positioning prevents moisture and oxygen from reaching critical components at the edge, avoiding lift-defects while maintaining structural integrity
2Area of stationary object
If the bank extends to the edge of the substrate, then the display area is maximized, but lift-defects occur due to moisture or oxygen exposure
Solution Approach 1:
The patent uses a composite multi-layer structure consisting of the bank, capping layer, overcoat layer, color filters, and second overcoat layer. Each layer provides different protective functions, creating a composite barrier system that resists moisture and oxygen penetration while allowing the bank to extend to the substrate edge for maximum display area
Solution Approach 2:
The protective layers are nested within and around the bank structure, with the capping layer covering the bank, the overcoat layer covering the capping layer, and color filters stacked vertically. This nested arrangement creates a protective envelope that shields the bank from moisture and oxygen while maintaining structural compactness
3Reliability
If multiple layers are stacked vertically in the non-display area, then light leakage is prevented, but device complexity increases
Solution Approach 1:
The vertically stacked layers in the non-display area serve multiple functions simultaneously: the capping layer provides structural coverage and light blocking, the overcoat layer adds protective coating, the color filters block specific wavelengths of light, and the second overcoat layer provides final protection. This multi-functionality reduces the need for separate components, managing complexity while achieving effective light leakage prevention
Data Source
AI summary
The display device includes a substrate including a display area and a non-display area, a light-emitting element layer in the display and non-display areas, a color conversion layer including a bank in the display and non-display areas, a capping layer in the display and non-display areas and covering the bank, a plurality of color filters in the display and non-display areas and the plurality of color filters in the non-display area overlapping each other, and an overcoat layer in the display and non-display areas and covering the plurality of color filters. Each of the substrate, the capping layer, the plurality of color filters, and the overcoat layer has a lateral side which is furthest from the display area, and the lateral sides of the substrate, the capping layer, each of the plurality of color filters, and the overcoat layer are aligned with one another.