Display Panel Recess Organic Auxiliary Layer Stress Relief
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Solution Overview
Problem
Display panels face issues with edge fragility and stress concentration during manufacturing, leading to cracks and water vapor/oxygen penetration due to mechanical and laser cutting methods, which damage the thin film encapsulation layer and light-emitting devices.
Innovation Solution
A display panel design featuring a substrate with a first inorganic insulating layer having a recess in the non-display area, filled with an organic auxiliary layer, and covered by an inorganic encapsulation layer with a penetrating opening, which relieves stress and prevents crack propagation by varying material expansion coefficients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical cutting is used to separate display panels from the mother panel, then the manufacturing efficiency is improved, but the thin film encapsulation layer cracks due to pressure from the cutter head
Solution Approach 1:
A release layer is introduced between the thin film encapsulation layer and the array layer, positioned to be removed before the cutting process. This preliminary action prepares the structure to withstand mechanical cutting by allowing the cutter head to contact only the release layer and substrate, not the fragile thin film encapsulation layer
Solution Approach 2:
The release layer serves as an intermediary between the cutter head and the thin film encapsulation layer during mechanical cutting. It absorbs the mechanical pressure and stress, preventing direct transmission of cutting forces to the encapsulation layer, thus avoiding cracks while enabling efficient mechanical separation
2Manufacturing precision
If laser cutting is used to separate display panels from the mother panel, then the manufacturing precision is improved, but cracks occur due to thermal effect
Solution Approach 1:
The release layer acts as a thermal intermediary during laser cutting, absorbing and dissipating thermal energy before it reaches the thin film encapsulation layer. This prevents thermal-induced cracks while allowing precise laser cutting to proceed
Solution Approach 2:
The release layer is strategically positioned and removed after serving its protective function during cutting. It is extracted from the final product structure, having fulfilled its purpose of preventing thermal damage during the manufacturing process
3Area of stationary object
If the display panel edge is made thinner to reduce size, then the area is reduced, but the edge becomes more fragile and prone to stress concentration
Solution Approach 1:
The release layer is selectively positioned at the edge regions where cutting occurs, providing localized reinforcement and stress distribution. This allows the main display area to remain thin while the edges gain enhanced structural properties where 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 reduces the risk of cracking and edge damage, maintaining the integrity of the display panel by alleviating stress and preventing water vapor/oxygen penetration, while simplifying the manufacturing process without additional steps.
Implementation Method 1
the organic auxiliary layer having a different thermal expansion coefficient from that of the at least one inorganic encapsulation layer
Data Source
AI summary
The present disclosure provides a display panel including: a substrate; an array layer located on the substrate and including a first inorganic insulating layer, and the first inorganic insulating layer including a first recess in the non-display area; a light-emitting function layer located on the array layer; a thin film encapsulation layer on the light-emitting function layer; and an organic auxiliary layer filled in the first recess. The thin film encapsulation layer includes at least one inorganic encapsulation layer covering the display area and extending to contact and cover the organic auxiliary layer in the first recess; and the at least one inorganic encapsulation layer includes a first opening located on the organic auxiliary layer in the recess. The present disclosure further provides a method of manufacturing the display panel and a display apparatus including the display panel.