Thin-Film Encapsulation Layout to Contain OLED Edge Overflow
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Solution Overview
Problem
Existing display devices face challenges in reducing the dead space and preventing the overflow of organic material from the thin film encapsulation layer, which can lead to inefficiencies and potential damage to the display panel.
Innovation Solution
The display device incorporates a design with a thin film encapsulation layer that includes a dam structure and insulating layers with concave shapes to block the flow of the organic encapsulation layer, along with a dam and insulating patterns to manage the organic material effectively, reducing the dead space and preventing overflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the dead space of the display panel is reduced, then the area utilization is improved, but the organic material may overflow outside the display panel
Solution Approach 1:
The encapsulation structure is divided into multiple functional zones including a light-emitting area, a valley area with lower encapsulation layers, and a peak area with higher encapsulation layers. This segmentation allows the organic material to be contained in lower areas while higher areas prevent overflow, enabling reduced dead space without risking material leakage.
Solution Approach 2:
Different regions of the encapsulation layer are given different heights and properties: the valley area has lower encapsulation layers allowing light emission, while the peak area has higher encapsulation layers that act as barriers. This local differentiation in structure and function enables both compact design and overflow prevention.
2Area of stationary object
If the organic material is allowed to spread freely, then the encapsulation coverage is improved, but the organic material overflows outside the display panel
Solution Approach 1:
The encapsulation layers are pre-formed with specific height variations (valley and peak areas) before the organic material is applied. The peak areas with higher encapsulation layers are prepared in advance to act as containment barriers, allowing the organic material to spread coverage without risking overflow beyond the display panel boundaries.
3Area of stationary object
If the dead space is reduced by bringing signal lines closer to the display area, then the area efficiency is improved, but the organic material may short-circuit the signal lines
Solution Approach 1:
The solution moves from a two-dimensional planar arrangement to a three-dimensional vertical structure. By creating height differences with valley and peak areas, the encapsulation layers provide vertical protection over the signal lines in the non-display area, allowing close positioning without short-circuit risk.
Solution Approach 2:
The encapsulation layers act as an intermediary protective barrier between the organic material and the signal lines. The peak areas with higher encapsulation layers specifically position this protective barrier over the signal lines in the non-display area, preventing direct contact between organic material and conductive elements.
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A display device includes a base layer, a circuit layer, a light emitting element layer, and a thin film encapsulation layer. The base layer includes a display area and a non-display area. The circuit layer includes a plurality of insulating layers, at least one of which has an opening. The light emitting element layer includes a light emitting area overlapping the display area, a valley area overlapping the opening and having a concave shape, and a peak area overlapping the non-display area and being on the circuit layer. The thin film encapsulation layer includes an organic encapsulation layer that covers the light emitting area, the valley area, and at least a portion of the peak area.