Glass Cap Recesses for UV Sealant Curing

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Solution Overview

Problem

In the process of bonding a glass cap to a substrate for organic electroluminescent devices, ultraviolet rays used to cure the sealant often inadvertently damage active areas due to diffusion and refraction issues, and incomplete curing occurs due to interference from metal lines.

Innovation Solution

Forming recesses on the glass cap with light non-transmittable layers corresponding to active areas on the substrate, allowing ultraviolet rays to cure the sealant without exposing active areas, and using a mask with varying light non-transmittable layers to intercept stray rays and ensure complete sealant curing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ultraviolet rays are irradiated to cure the sealant on the substrate bonding region, then the sealant is cured and the cap is securely bonded, but the ultraviolet rays damage the active areas due to diffusion and refraction

Engineering Contradiction:

Improvebonding reliabilityVSAvoidultraviolet ray damage to active areas

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The glass cap is segmented by forming recesses corresponding to each active area, creating physical barriers that block ultraviolet rays from reaching the active areas while allowing the sealant in bonding regions to be cured

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Light non-transmittable layers are introduced as an intermediary between the ultraviolet light source and the active areas, selectively blocking harmful rays while allowing the curing process to proceed in safe regions

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If a mask is used to protect active areas from ultraviolet rays, then damage to active areas is prevented, but incomplete curing of sealant occurs due to interference from metal lines

Engineering Contradiction:

Improveprotection of active areasVSAvoidcuring completeness

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

Instead of placing the mask on the substrate side, the protective structure is inverted and placed on the glass cap side, with recesses formed directly in the cap to block ultraviolet rays before they can reach the active areas

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The recesses in the glass cap are formed as copies of the active area patterns, creating a complementary structure that naturally aligns to protect active areas without requiring precise mask registration

Inventive Principle:

Principle #26Copying

3Stability of the object's composition

If the glass cap is made thick to prevent transformation by pressure, then structural stability is improved, but ultraviolet rays cannot penetrate to cure the sealant completely

Engineering Contradiction:

Improvestructural stabilityVSAvoidcuring completeness

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The glass cap has non-uniform thickness with recesses creating localized thin regions that allow ultraviolet ray penetration for sealant curing, while the overall cap structure remains sufficiently thick for structural stability and pressure resistance

Inventive Principle:

Principle #3Local quality

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 method prevents damage to active areas and ensures complete curing of the sealant, maintaining device functionality and allowing for secure adhesion without the need for precise mask alignment.

Implementation Method 1

forming a plurality of light non-transmittable layers on a surface of the glass opposite to a surface corresponding to the substrate

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Implementation Method 2

curing the sealant dispensed on the sealing-dispensing region by irradiating the ultraviolet rays to a side of the glass to which the substrate is not bonded

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS8303756B2Method for bonding a glass cap and mask for curing sealant

Publication Date: 2012.11.06 LG DISPLAY CO LTD

AI summary

The method for bonding a glass cap according to the present invention comprises the steps of, forming a plurality of recesses on a side of a glass corresponding to a substrate; forming a plurality of light non-transmittable layers on a surface of the glass opposite to a surface corresponding to the substrate; dispensing a sealant on a substrate-bonding region of the glass or on a cap-bonding region of the substrate; bonding the glass to the substrate in the state that each active area formed on the substrate is received in each recess of the glass; curing the sealant dispensed on the sealing-dispensing region by irradiating ultraviolet rays to a side of the glass to which the substrate is not bonded; and dicing the bonded glass and substrate to make the individual devices. The present invention intercepts the ultraviolet rays irradiated to the active areas of the substrate to protect the active areas, and so can cure completely the sealant dispensed on the metal lines.