Display Panel Gap Design for Void Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional display panels suffer from void formation in the sealing resin layer, which leaves light-emitting elements uncovered, leading to potential deterioration from water and oxygen infiltration.
Innovation Solution
The display panel design features a specific distance relationship between the element substrate and the opposing substrate, where the distance is narrower at light-emitting element locations to enhance resin fluidity and prevent void formation, while being wider in inter-pixel areas to minimize resin flow and induce voids in non-critical areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If resin material is dropped in volumes sufficient to cover multiple light-emitting elements, then the sealing resin layer can be formed over a wide area, but voids remain in the sealing resin layer where unfilled by the resin material
Solution Approach 1:
The patent applies local quality by creating different gap widths in different regions: narrower gap widths under light-emitting elements to ensure complete resin filling and prevent voids, and wider gap widths in inter-pixel areas where voids are acceptable. This spatial variation in gap geometry allows the sealing resin layer to achieve both wide area coverage and high manufacturing precision in critical regions.
2Manufacturing precision
If the distance between element substrate and opposing substrate is reduced to enhance resin fluidity, then void formation is prevented, but the structure becomes more compact with less space for resin flow
Solution Approach 1:
The patent implements local quality by varying the gap width between substrates: narrower gaps (smaller volume) under light-emitting elements where void prevention is critical, and wider gaps (larger volume) in inter-pixel areas where resin flow space is sufficient and voids are less problematic. This resolves the contradiction by allocating volume resources according to functional requirements.
3Area of stationary object
If resin material is dropped at multiple positions to cover the entire area, then complete coverage is achieved, but resin material mutually overlaps and creates concentric circle patterns that may trap air
Solution Approach 1:
The patent uses local quality by creating narrower gap regions under light-emitting elements that act as void-trapping zones. When resin material spreads in concentric circles from multiple drip positions, these narrow gap regions ensure complete filling and prevent air entrapment, while wider gap regions in inter-pixel areas accommodate the overlapping resin patterns without critical consequences.
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 design effectively constrains void formation over light-emitting elements, ensuring better protection against environmental degradation and maintaining display quality by directing voids to non-critical areas.
Implementation Method 1
a sealing resin layer interposed between and adjoining the element substrate and the opposing substrate... the sealing layer sealing the light-emitting elements
Implementation Method 2
the dropped resin material 24 spreads in concentric circles, expanding from the center of each drip position
Data Source
AI summary
A display panel enabling constraint of void formation between substrates and minimizing the effect of any voids formed, has for at least one pixel, a distance between the element surface and the element opposing surface corresponding to each light-emitting element of the pixel that is smaller than a distance between the inter-pixel surface and the inter-pixel opposing surface in an inter-pixel area between neighboring pixels, and smaller than a distance between the inter-element surface and the inter-element opposing surface corresponding to the light-emitting elements, and on the element substrate, the distance between neighboring pixels is greater than a distance between neighboring light-emitting elements, and a distance between the inter-pixel surface and the inter-pixel opposing surface is greater than a maximum distance between the inter-element surface and the inter-element opposing surface.