Display Panel Sealing Structure for Precise Substrate Alignment
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Solution Overview
Problem
Current flat display panels face alignment errors during assembly due to displacement or rotation of substrates, leading to misalignment of light-emitting regions and color filter layers, which affects the accuracy and performance of the display device.
Innovation Solution
The implementation of a display device design that includes a substrate with a light-emitting unit consisting of a bottom electrode layer, a light-emitting layer, and a top electrode layer, along with dams on the substrate in the non-active region, and a sealing layer that extends from the active to the non-active region to ensure precise alignment and prevent water and oxygen intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two substrates are bonded or pressed together during assembly, then the display panel can be manufactured, but alignment errors occur due to displacement or rotation of substrates
Solution Approach 1:
Alignment marks are pre-formed on both substrates before the bonding process. These marks serve as reference points that guide the alignment process, enabling operators to detect and correct any displacement or rotation before final bonding occurs, thus preventing alignment errors rather than correcting them after assembly
Solution Approach 2:
The alignment marks provide visual feedback during the assembly process. By observing the relative positions of corresponding alignment marks on both substrates, operators can determine whether displacement or rotation has occurred and adjust the substrate positions accordingly before bonding, ensuring accurate alignment
2Reliability
If the topmost surface of dams is lower than the top electrode layer, then water and oxygen intrusion is prevented, but the structural complexity increases
Solution Approach 1:
The dams are designed with a specific local geometry where the topmost surface is lower than the top electrode layer in the non-active region. This localized structural feature creates a barrier that prevents water and oxygen from reaching the electrode layers at the edges, providing enhanced protection exactly where it is needed without requiring complex modifications throughout the entire device structure
Data Source
AI summary
A display device having an active region and a non-active region, includes a substrate layer having a surface, a bottom electrode layer, a light-emitting layer and a top electrode layer stacked sequentially on the surface of the substrate layer in the active region, and a plurality of first dams. A portion of the bottom electrode layer, a portion of the light-emitting layer and a portion of the top electrode layer are served as a light-emitting unit. The plurality of first dams is disposed on the surface of the substrate layer in the non-active region, wherein a distance between a topmost surface of at least one of the plurality of first dams and the surface of the substrate layer is less than a distance between a topmost surface of the top electrode layer and the surface of the substrate layer.