Display Device Spacer Groups for Vapor Mask Stability
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Solution Overview
Problem
Display devices using vapor deposition masks and ink-jet methods for forming light-emitting layers and sealing layers suffer from display unevenness due to uneven spacer densities, leading to thickness variations in the resin layer, which affects display quality and frame narrowing.
Innovation Solution
A display device design with specific spacer configurations, including first, second, and third spacers with varying densities and orientations, along with edge covers and trenches, to stabilize the vapor deposition mask and control resin layer spread, ensuring uniform thickness across the display region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the vapor deposition mask is disposed to face the frame region with no openings, then the mask structure is simple, but the mask weight becomes heavier causing deflection
Solution Approach 1:
The patent applies local quality by providing openings in the vapor deposition mask at specific locations (display region and portions of frame region) rather than uniformly across the entire mask. This allows the mask to have different structural properties in different areas - lighter in the display region where openings are provided, and more substantial in the frame region where openings are not provided, thereby balancing weight distribution and preventing deflection while maintaining structural simplicity.
2Stability of the object's composition
If spacers are provided at high density in the frame region to support the mask, then mask deflection is prevented, but the resin layer thickness becomes uneven
Solution Approach 1:
The patent applies local quality by providing spacers at different densities in different regions. High density spacers are provided in the frame region to support the vapor deposition mask and prevent deflection, while low density spacers are provided in the display region to allow uniform resin layer formation. This regional differentiation resolves the contradiction between mask support stability and resin layer thickness uniformity.
Solution Approach 2:
The patent segments the spacer structure into different types (first spacers in display region, second spacers in frame region) with different densities and functions. This segmentation allows each spacer type to optimize for its specific regional requirement, preventing the uniform spacer density from causing either mask deflection or resin layer unevenness.
3Area of stationary object
If the display region area is increased, then display quality improves, but the frame region becomes narrower affecting structural support
Solution Approach 1:
The patent applies local quality by providing openings in the vapor deposition mask at specific locations (display region and portions of frame region) rather than uniformly across the entire mask. This allows the mask to have different structural properties in different areas - lighter in the display region where openings are provided, and more substantial in the frame region where openings are not provided, thereby balancing weight distribution and preventing deflection while maintaining structural simplicity.
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 enhances display quality by preventing resin layer thickness variations, thereby reducing display unevenness and allowing for narrower frames in the display device.
Implementation Method 1
a vapor deposition mask is used for manufacturing the display device including the OLED
Implementation Method 2
a resin layer included in a sealing layer is formed by an ink-jet method
Data Source
AI summary
A display device includes: a substrate, a thin film transistor layer; a display region and a frame region; a light-emitting element layer including a first electrode, a light-emitting layer, and a second electrode in this order from the thin film transistor layer side; a peripheral electrode; an edge cover configured to cover an edge of the first electrode and an edge of the peripheral electrode; a plurality of spacers provided in the display region and the frame region; and a sealing layer. The plurality of spacers includes a plurality of third spacers provided on the edge cover in the frame region. A plurality of third spacer groups including a plurality of adjacent third spacers of the plurality of third spacers is provided. Each of the plurality of third spacer groups is provided in parallel to each other and in a direction intersecting an edge of the display region.