Flat Panel Display Encapsulation Preventing Edge Tail Permeation
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Solution Overview
Problem
Existing encapsulation structures for flat panel display devices suffer from moisture and oxygen permeation due to the formation of edge tails at the interface between organic and inorganic layers, which compromises the device's performance.
Innovation Solution
A method involving the use of an organic layer mask with a regulator and tunnel to form a condensor, and an inorganic layer mask with an eave unit, ensuring the organic layer is fully covered and preventing edge tail formation by using polyurea or polyacrylate for the organic layer and SiNx, Al2O3, SiO2, or TiO2 for the inorganic layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask is used to form the organic layer pattern, then the organic layer can be deposited, but the organic layer permeates the gap between the mask and substrate forming edge tails
Solution Approach 1:
The patent applies preliminary action by forming an inorganic layer mask with an eave unit that extends beyond the mask body before depositing the inorganic layer. This eave unit pre-establishes an overhang structure that will subsequently cover the edge tail of the organic layer, preventing moisture and oxygen permeation before the problem occurs.
Solution Approach 2:
The patent segments the mask structure into distinct functional parts: the mask body for defining the pattern area and the eave unit extending from it for preventing edge tail exposure. This segmentation allows each component to perform its specific function independently, with the eave unit specifically addressing the edge tail problem.
2Manufacturing precision
If the mask is scraped to remove the gap, then organic layer permeation is reduced, but the mask does not distinctly regulate the boundary and edge tails still form
Solution Approach 1:
Instead of trying to eliminate the gap after mask placement, the invention performs preliminary action by creating the eave unit structure before inorganic layer deposition. This pre-formed overhang ensures that even if organic layer edge tails form, they will be covered by the eave unit, distinctly regulating the boundary without requiring gap removal.
3Reliability
If the organic layer is deposited to cover the display, then the display is protected, but edge tails form at the boundary allowing moisture and oxygen to permeate
Solution Approach 1:
The patent resolves the two-dimensional boundary problem by introducing a third dimension - the eave unit extends vertically beyond the mask body plane, creating an overhang structure. This dimensional change allows the inorganic layer to cover the organic layer edge tails from above, blocking moisture and oxygen permeation paths that exist at the boundary.
Solution Approach 2:
The eave unit acts as beforehand cushioning by pre-positioning a protective structure that will cover the organic layer edge tails. This preventive measure is built into the mask structure before deposition, cushioning against the potential harmful effect of edge tail formation and subsequent moisture/oxygen permeation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly enhances water vapor transmission resistance and prevents performance deterioration by ensuring the organic layer is fully encapsulated, eliminating edge tails and thus effectively sealing the display device.
Implementation Method 1
condensing a part of the organic layer permeating through the tunnel
Implementation Method 2
The organic layer is formed by depositing a liquid monomer on the display and radiating UV light onto the deposited liquid monomer on the display so as to polymerize the liquid monomer
Data Source
AI summary
A flat panel display device and a method of manufacturing the same. The method of manufacturing the flat panel display device includes: forming a display on a substrate; preparing an organic layer mask comprising a first mask body, a regulator extending from the first mask body and contacting the organic layer, and a tunnel having a space between the first mask body and the regulator; forming an organic layer covering the display in a region divided by the regulator of the organic layer mask, and condensing a part of the organic layer permeating through the tunnel; preparing an inorganic layer mask; and forming an inorganic layer covering the organic layers formed in the region divided by the regulator through the inorganic layer mask and in the tunnel.