Flexible Display Gas Barrier Layer Design
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Solution Overview
Problem
Large-sized flexible organic light emitting diode display devices face challenges in achieving flexibility and thinness due to the limitations of glass-based sealing substrates, and thin film encapsulation processes have low manufacturing yields.
Innovation Solution
A flexible display device structure comprising a first and second flexible substrate, a display part, a color filter, an overcoat layer, a gas barrier layer, and an encapsulation part with a filler and sealant, where the gas barrier layer is larger than the encapsulation part and formed from materials like silicon nitride or silicon oxide, enhancing sealing performance and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a glass-based sealing substrate is used for large-sized display devices, then sealing performance is improved, but flexibility and thinness are compromised
Solution Approach 1:
The patent replaces the rigid glass-based sealing substrate with flexible substrates (first flexible substrate and second flexible substrate) that can be bent and folded. The encapsulation part uses flexible sealant materials that maintain sealing performance while enabling the display device to achieve flexibility and thinness, directly resolving the contradiction between sealing performance and adaptability.
2Adaptability or versatility
If thin film encapsulation is used to achieve flexibility, then flexibility is improved, but manufacturing yield decreases
Solution Approach 1:
The patent divides the encapsulation structure into separate functional components: first and second flexible substrates, encapsulation part with sealant, color filter, and gas barrier layer. This segmentation allows each component to be optimized and manufactured independently, then assembled together, improving manufacturing yield while maintaining flexibility.
Solution Approach 2:
The patent applies the gas barrier layer and color filter to the second flexible substrate before final assembly with the first flexible substrate. This preliminary preparation of components separately allows for quality control and defect detection before final encapsulation, reducing manufacturing defects and improving overall yield.
3Adaptability or versatility
If thin film encapsulation is used for large-sized devices, then flexibility is achieved, but device thickness increases
Solution Approach 1:
The patent uses ultra-thin flexible substrates and sealant materials that provide the necessary sealing and flexibility functions with minimal thickness. The encapsulation part is formed as a thin flexible structure rather than a bulky rigid enclosure, enabling the display device to be both flexible and thin simultaneously.
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 enables large and thin flexible display devices with improved sealing performance and increased manufacturing yield, eliminating the need for glass-based sealing substrates and reducing the complexity of the encapsulation process.
Implementation Method 1
a gas barrier layer, and an encapsulation part. The gas barrier layer is positioned between the display part and the overcoat layer, and covers the overcoat layer
Implementation Method 2
The encapsulation part includes a filler positioned between the display part and the gas barrier layer, and a sealant positioned at an outside of the filler
Data Source
AI summary
A flexible display device includes: a first flexible substrate and a second flexible substrate facing each other; a display part positioned on a surface of the first flexible substrate facing the second flexible substrate and including a plurality of thin film transistors and a plurality of light emitting elements; a color filter positioned on a surface of the second flexible substrate facing the first flexible substrate; an overcoat layer positioned between the display part and the color filter and covering the color filter; a gas barrier layer positioned between the display part and the overcoat layer and covering the overcoat layer; and an encapsulation part including a filler positioned between the display part and the gas barrier layer, and a sealant positioned at an outside of the filler, and an area of the gas barrier layer is larger than an area of the encapsulation part.