Encapsulation Film Overlap Prevents Pad Electrode Arcing
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Solution Overview
Problem
Organic light emitting display devices face issues with arcing between masks and pad electrodes during manufacturing, leading to defects due to high currents flowing along the pad electrodes, and the encapsulation film can overflow outside intended areas, causing manufacturing challenges.
Innovation Solution
A display device design featuring a first substrate with a display area, a non-display area surrounded by a dam, and a pad electrode outside the dam, with an encapsulation film comprising a first and second inorganic film that overlaps the pad electrode, eliminating the need for a mask over the pad area and preventing arcing by acting as an insulating film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask is arranged on the pad electrode to prevent inorganic film formation, then the inorganic film is kept from forming on the pad area, but arcing occurs between the mask boundary surface and the pad electrode causing high current defects
Solution Approach 1:
The patent removes the mask component entirely from the pad area by extending the encapsulation film to cover it. The encapsulation film serves dual purposes: protecting the organic light emitting diode and preventing inorganic film formation on the pad electrode, eliminating the need for a separate mask and thus preventing arcing defects.
Solution Approach 2:
The encapsulation film is extended to perform multiple functions: it encapsulates the organic light emitting diode to prevent water and oxygen permeation, and simultaneously covers the pad electrode to prevent inorganic film formation and eliminate arcing risks. This multi-functional approach replaces the need for separate mask components.
2Reliability
If the encapsulation film is formed to cover the pad area, then arcing is prevented, but the organic film may overflow outside the intended encapsulation area
Solution Approach 1:
The dam is formed beforehand to define the boundary of the encapsulation film. The encapsulation film is then deposited to cover the pad electrode area up to the dam structure, preventing overflow while ensuring complete coverage of the pad electrode for arcing prevention.
3Manufacturing precision
If a mask is used to cover the pad electrode, then inorganic film formation is prevented, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The mask component and its associated alignment and deposition processes are completely removed from the manufacturing process. The encapsulation film itself is extended to perform the protective function previously requiring a separate mask, simplifying the manufacturing process and reducing costs.
Solution Approach 2:
The encapsulation film is designed to serve multiple functions: protecting the organic light emitting diode from environmental degradation and preventing inorganic film formation on the pad electrode. This eliminates the need for separate mask components and reduces manufacturing complexity.
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
This solution prevents arcing and defects by ensuring the encapsulation film does not overflow and acts as an insulating layer, reducing manufacturing complexity and costs by eliminating the need for a mask over the pad area.
Implementation Method 1
acts as an insulating film to prevent arcing
Data Source
AI summary
A display device and a method of manufacturing the same are disclosed, in which arcing may be prevented from occurring. The display device comprises a first substrate including a display area on which pixels are arranged, and a non-display area surrounding the display area; a dam surrounding the display area, arranged on the non-display area; a pad electrode arranged outside the dam; and an encapsulation film covering the display area and including a first inorganic film and a second inorganic film arranged on the first inorganic film, wherein the second inorganic film is overlapped with the pad electrode.