Display Device Metal Capping Layer for Open-Area Crack and Moisture Control
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Solution Overview
Problem
The challenge of forming an open area in a display device's display area for accommodating optical devices like cameras and sensors leads to substrate cracking, moisture infiltration, and static-electricity issues, which can damage the display panel and reduce its lifespan.
Innovation Solution
A capping layer made of metal material is disposed on the intermediate area between the display and open areas, forming a closed loop to prevent moisture penetration, crack propagation, and provide a discharge path for static-electricity, thereby enhancing the display device's robustness and reducing power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a precise cutting process using laser is performed to form an open area in the substrate, then the open area can be accurately formed to accommodate optical devices, but a large amount of energy accumulates in a local area causing cracks to occur in the substrate
Solution Approach 1:
A capping layer is introduced as an intermediary component between the substrate and the open area. This capping layer serves as a mediator that prevents crack propagation from the open area into the display area while maintaining the structural integrity of the substrate. The capping layer absorbs and distributes the stress and energy concentration caused by laser cutting, preventing substrate damage.
Solution Approach 2:
The capping layer is formed beforehand to cover and protect the open area before the laser cutting process is performed. This prior protective measure cushions the substrate against the harmful effects of laser energy accumulation and prevents cracks from forming or propagating during the cutting process.
2Adaptability or versatility
If the open area is formed by removing substrate, light-emitting layers, and insulating layers, then optical devices can be disposed in the open area, but cracks in the substrate act as moisture penetration paths leading to light-emitting element defects
Solution Approach 1:
The capping layer acts as an intermediary protective barrier that seals the open area and prevents moisture from penetrating through substrate cracks to reach the light-emitting elements. This mediator layer maintains the reliability of the light-emitting elements while allowing the open area to accommodate optical devices.
Solution Approach 2:
The capping layer functions as a thin film structure that covers the open area and provides a flexible yet effective moisture barrier. This thin film prevents moisture infiltration along crack paths while maintaining the structural integrity and allowing for the integration of optical devices in the open area.
3Strength
If crack propagation prevention structures are disposed to block crack paths, then crack propagation is prevented, but step structures cause seam-like defects in the inorganic insulating layer that act as moisture permeation paths
Solution Approach 1:
The capping layer serves as an intermediary protective layer that covers the open area and prevents moisture from accessing seam-like defects in the inorganic insulating layer. This mediator layer eliminates the harmful effect of moisture permeation through insulating layer seams while maintaining crack propagation prevention structures.
Solution Approach 2:
The capping layer forms a continuous thin film overlay that seals over the open area and any associated defects in underlying insulating layers. This film structure prevents moisture infiltration through seam-like defects while allowing crack prevention structures to maintain substrate strength.
4Manufacturing precision
If laser cutting is performed to form the open area, then the open area is precisely formed, but static-electricity is generated that may open electrodes or short-circuit adjacent electrodes
Solution Approach 1:
The capping layer acts as an intermediary protective layer during the laser cutting process. It serves as a barrier that prevents static-electricity generated during laser cutting from directly affecting the electrodes and circuits in the display area, thereby preventing electrode opening or short-circuiting while maintaining precise open area formation.
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
The solution effectively prevents moisture infiltration, crack propagation, and static-electricity discharge, improving the display device's lifespan and reducing power consumption while minimizing touch noise.
Implementation Method 1
when the precise cutting process using the laser is performed, static-electricity may be generated. The static-electricity generated in this way may open an electrode in the display panel or short-circuit adjacent electrodes to each other
Implementation Method 2
The cracks that occur in the cut area of the substrate may act as a moisture penetration path. The light-emitting elements positioned in the display area and containing the organic material are particularly vulnerable to moisture
Data Source
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AI summary
Disclosed is a display device (1) in which a capping layer (CL) surrounding an open area (OA) and including a metal material is disposed on an intermediate area (MA) between a display area (AA) and the open area (OA), thereby preventing moisture penetration from a position on top of an insulating layer through the insulating layer near the open area (OA).