Display Encapsulation Edge Layout for Non-Display Area Inspection
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Solution Overview
Problem
Existing display devices face challenges in effectively distinguishing between the edges of the encapsulation organic layer, second electrode, and protection layer, particularly in the non-display areas, which can lead to manufacturing defects and difficulties in identifying appropriate layer deposition during the production of light emitting display devices.
Innovation Solution
A display device configuration that includes a base layer with a display area and a non-display area, featuring a first electrode, a light emitting layer, a second electrode overlapping both areas, a protection layer, and a thin-film encapsulation layer with specific edge alignments and distances between the encapsulation organic layer, second electrode, and protection layer, along with manufacturing equipment using masks with concave and convex areas to precisely deposit materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the edges of the encapsulation organic layer, second electrode, and protection layer are closely aligned in the non-display area, then the device structure is more compact, but it becomes difficult to distinguish and inspect the layer edges during manufacturing
Solution Approach 1:
The patent extracts the inspection function from the main display area by creating a dedicated non-display area with spaced-apart layer edges. This separate region allows inspectors to clearly view and evaluate the edges of the encapsulation organic layer, second electrode, and protection layer without interference from display elements, thus solving the contradiction between compact structure and inspectability.
Solution Approach 2:
The patent introduces an intermediary inspection area that mediates between the compact device structure and the need for edge identification. This intermediate region provides a buffer zone where layer edges are deliberately spaced apart, serving as a transition area that maintains overall device compactness while enabling effective visual inspection of layer alignment and deposition quality.
2Difficulty of detecting and measuring
If the layer edges are spaced apart in the non-display area, then edge inspection becomes easier, but the device occupies more area
Solution Approach 1:
The patent applies local quality by creating different spatial configurations in different regions of the device. In the display area, layers are closely aligned for compactness, while in the non-display inspection area, layers are deliberately spaced apart. This localized differentiation allows the device to achieve both compact overall dimensions and effective edge inspection capability.
3Manufacturing precision
If multiple layers are deposited with precise edge alignment, then manufacturing precision is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent implements preliminary action by pre-designing the layer structure with spaced-apart edges in the non-display area before the actual deposition process. This preliminary structural arrangement simplifies the manufacturing process by providing clear visual references during deposition, making it easier to achieve precise edge alignment without requiring overly complex real-time control systems.
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 configuration allows for improved inspection and identification of layer edges, reducing manufacturing defects and ensuring accurate deposition of layers, thereby enhancing the reliability and quality of light emitting display devices.
Implementation Method 1
a first mask configured to deposit a first material on each of unit areas of a working substrate, and a second mask configured to deposit a second material on each of the unit areas of the working substrate
Data Source
AI summary
A display device includes an electrode, a protection layer disposed on the electrode, and an encapsulation organic layer disposed on the protection layer. In a first area, an edge of the encapsulation organic layer is spaced a first distance from an edge of the electrode, and the edge of the encapsulation organic layer is spaced a second distance from an edge of the protection layer. In the second area, the edge of the encapsulation organic layer is disposed between the edge of the electrode and the edge of the protection layer. In the second area, the edge of the encapsulation organic layer is spaced a third distance, greater than the first distance, from the edge of the electrode, and the edge of the encapsulation organic layer is spaced a fourth distance, greater than the second distance, from the edge of the protection layer.