Display Panel Metal Layer Oxidation Prevention
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Solution Overview
Problem
Display panels experience oxidation of electrodes and layers at high temperature and high humidity, leading to reliability issues due to moisture permeation and reduced adhesion between inorganic encapsulation layers and the insulating layer.
Innovation Solution
A display panel design featuring an inorganic insulating layer, a bank with a metal layer including conductive oxide on its surface, and an encapsulation layer structure that includes discontinuous inorganic layers and an organic layer, with a metal layer extending to prevent moisture ingress and oxidation, along with a manufacturing method that forms these layers on a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional encapsulation structure is used, then the display panel can be manufactured with standard processes, but oxidation of electrodes and layers occurs at high temperature and high humidity leading to reliability issues
Solution Approach 1:
The patent employs a composite encapsulation structure combining organic and inorganic encapsulation layers. The inorganic encapsulation layer (e.g., aluminum oxide, titanium oxide) provides superior oxidation resistance and moisture barrier properties, while the organic encapsulation layer offers flexibility and stress relief. This composite approach resolves the contradiction by achieving enhanced reliability through oxidation resistance while maintaining manufacturability through established multi-layer deposition techniques.
Solution Approach 2:
The patent introduces an intermediary metal layer (such as tungsten, molybdenum, or titanium) between the inorganic encapsulation layer and the electrode structures. This intermediary layer serves as a diffusion barrier that prevents oxygen and moisture from reaching the electrodes, thereby preventing oxidation. The mediator layer enables the system to achieve high reliability without requiring the inorganic encapsulation layer to be in direct contact with sensitive electrodes, simplifying the overall design while maintaining protection.
2Reliability
If the inorganic encapsulation layer is made continuous to improve protection, then oxidation resistance increases, but adhesion between the inorganic encapsulation layer and insulating layer deteriorates
Solution Approach 1:
The patent segments the inorganic encapsulation layer into discontinuous portions rather than forming a continuous film. By creating isolated regions of inorganic material strategically positioned over critical areas, the patent maintains oxidation protection where needed while preventing the adhesion problems that arise from continuous deposition. This segmentation allows the insulating layer to maintain its integrity and adhesion properties while still receiving protective coverage.
Solution Approach 2:
The patent applies local quality by providing inorganic encapsulation only in specific regions where oxidation protection is most critical, rather than uniformly across the entire surface. The inorganic encapsulation layer is positioned locally over electrodes and conductive structures that are most susceptible to oxidation, while other areas rely on the organic encapsulation layer. This localized approach maintains adhesion strength in areas where inorganic material would cause problems while providing protection where it is most needed.
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 or reduces oxidation of electrodes and layers, enhancing the display panel's reliability by blocking moisture and maintaining adhesion between layers, thus preventing damage to the inorganic insulating layer and extending the panel's operational lifespan.
Implementation Method 1
when reliability of a display panel progresses at high temperature and high humidity, electrodes included in the display panel or at least some of the layers included in the display panel may be oxidized
Implementation Method 2
effectively prevents or reduces oxidation of electrodes and layers, enhancing the display panel's reliability by blocking moisture
Implementation Method 3
maintaining adhesion between layers, thus preventing damage to the inorganic insulating layer
Data Source
AI summary
A display panel includes: a substrate comprising a display area, an opening area, a middle area, and a peripheral area outside the display area; an inorganic insulating layer on the substrate; a bank on the inorganic insulating layer in the peripheral area; and a metal layer on at least a portion of an upper surface of the bank and on a lateral surface adjacent to the display area among lateral surfaces of the bank, the metal layer comprising a conductive oxide.