Display Panel Filling Layer for Foreign Substance Isolation
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Solution Overview
Problem
Display devices using organic electroluminescent or quantum dot light emitting materials are vulnerable to environmental contamination, leading to reduced display quality and reliability due to foreign substances introduced during manufacturing, which expose the light emitting material to external environment through cracks.
Innovation Solution
A display device design with a filling layer between panels, including a protruding area to cover foreign substances, and a multi-layer encapsulation structure with inorganic and organic layers to protect the light emitting material, along with a method to correct brightness imbalances caused by foreign substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foreign substances are introduced during manufacturing, then the light emitting material is exposed to external environment through cracks, but display quality and reliability deteriorate
Solution Approach 1:
The filling layer is formed in advance to cover and isolate foreign substances before they can cause cracks or environmental contamination. This preventive measure cushions the light emitting material from harmful effects by creating a protective barrier that fills gaps and prevents exposure to oxygen and moisture.
Solution Approach 2:
The filling layer acts as an intermediary substance between the light emitting material and foreign substances. It mediates the interaction by providing a protective interface that prevents direct contact between harmful foreign substances and the vulnerable light emitting material, thereby maintaining display reliability.
2Reliability
If the distance between display element layer and light control layer is increased in areas with foreign substances, then foreign substances are isolated, but brightness uniformity becomes challenging
Solution Approach 1:
The filling layer is applied selectively in local areas where foreign substances are present, creating varying thicknesses across different regions. The layer provides enhanced protection and isolation precisely where needed (at foreign substance locations) while maintaining appropriate thickness elsewhere, thus achieving both foreign substance isolation and brightness uniformity through localized quality adjustment.
Data Source
AI summary
A display device includes a first area in which a foreign substance is disposed and a second area in which the foreign substance is not disposed. The display device includes a lower panel including a base layer, a display element layer, and an encapsulation layer, an upper panel disposed on the lower panel and including a light control layer and a color filter layer, and a filling layer filling a space between the lower panel and the upper panel. A distance between the display element layer and the light control layer in the first area is greater than a distance between the display element layer and the light control layer in the second area. Accordingly, defects caused by the foreign substance are prevented, and a display quality and a reliability of the display device are increased.