Dual-Layer Gap Control for EL Display Sealing
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Solution Overview
Problem
Existing electro-luminescence devices face challenges in maintaining display quality due to irregularities in the gap between the function layer and the color filter, leading to moisture-related deterioration and potential damage to the gas barrier layer, which affects the sealing properties and aperture ratio.
Innovation Solution
The use of a dual-layer gap control system with different Young's moduli, where the uppermost gap control layer has a lower modulus than the gas barrier layer, allowing for surface contact without damaging the gas barrier layer and enabling precise control of the gap, thereby improving sealing and display capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a sphere-shaped gap control layer is used to suppress gap irregularity, then the gap uniformity is improved, but the gas barrier layer may suffer from local breakage due to point contact pressure
Solution Approach 1:
The gap control layer is divided into multiple layers with different materials and properties. The first gap control layer (lower layer) provides structural support and distributes pressure, while the second gap control layer (upper layer) with lower Young's modulus conforms to the gas barrier layer surface and suppresses gap irregularity. This segmentation allows each layer to perform its specific function without compromising the other.
Solution Approach 2:
The invention changes the physical parameter of Young's modulus across different gap control layer materials. The first gap control layer has a higher Young's modulus for mechanical strength, while the second gap control layer has a lower Young's modulus (lower than the gas barrier layer) to allow surface contact and conformability. This parameter variation enables the system to achieve both gap uniformity and gas barrier layer protection.
2Reliability
If a gap control layer with low Young's modulus is used to avoid gas barrier layer damage, then the gas barrier layer integrity is improved, but the gap irregularity increases
Solution Approach 1:
The gap control function is segmented between two layers: the first layer (higher Young's modulus) maintains structural integrity and prevents excessive deformation, while the second layer (lower Young's modulus) provides the conformability needed to suppress gap irregularity. This segmentation allows the system to simultaneously achieve both goals that cannot be met by a single material.
Solution Approach 2:
The gap control structure uses composite materials with different mechanical properties. The first gap control layer is made of a material with higher Young's modulus for rigidity, while the second gap control layer uses a material with lower Young's modulus for flexibility. This composite structure combines the advantages of both material types to achieve optimal performance.
3Reliability
If the gas barrier layer is formed to block water vapor effectively, then the sealing property is improved, but the aperture ratio decreases due to the need for additional protective layers
Solution Approach 1:
The gap control layers serve multiple functions simultaneously: they maintain the gap between the color filter and light emitting element, protect the gas barrier layer from damage during bonding, and contribute to the overall sealing structure. This multi-functionality reduces the need for separate protective layers, thereby minimizing the impact on aperture ratio while maintaining effective water vapor blocking.
Data Source
AI summary
There is provided an electro-luminescence device in which a display base substrate including a display body layer having a switching element disposed in the shape of a matrix and a light emitting element having a light emitting state controlled by the switching element and a sealing layer having a gas barrier layer that is formed on the display body layer and has at least a function for blocking water vapor and a protection substrate made of a translucent material and having a surface on which at least two types of gap control layers made of different materials are stacked are bonded such that a gap control layer, disposed on the uppermost layer, of the gap control layers and the gas barrier layer are brought into contact with each other, wherein the gap control layer disposed on the uppermost layer has a Young's modulus lower than the gas barrier layer.