Laser Barrier Layer Protects Metal Electrode During Flexible OLED Cutting

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Solution Overview

Problem

The half-cutting process in preparing flexible OLED display panels is challenging due to a thin contact film layer, which easily damages the underlying metal electrode, increasing the difficulty and cost of laser debugging and reducing yield.

Innovation Solution

A laser barrier layer is introduced between the lead metal layer and the protective film layer, made of materials like amorphous silicon or reflective materials, to prevent damage during laser cutting by absorbing or reflecting laser energy, thereby protecting the metal electrode.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If laser cutting is used to cut the protective film layer, then the cutting process can be performed, but the thin contact film layer easily damages the underlying metal electrode

Engineering Contradiction:

Improvecutting process efficiencyVSAvoidmetal electrode integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A laser barrier layer is introduced as an intermediary between the protective film layer and the lead metal layer. This barrier layer absorbs or reflects laser energy, preventing direct laser exposure to the metal electrode during the cutting process. The barrier layer acts as a mediator that protects the underlying metal electrode from damage while allowing the cutting process to proceed efficiently.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The laser barrier layer is deposited beforehand on the lead metal layer to provide protective cushioning against laser energy. This prior protection measures prevents potential damage to the metal electrode during subsequent laser cutting operations, ensuring the integrity of the electrode while maintaining cutting efficiency.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Ease of manufacture

If the contact film layer is made thin to facilitate cutting, then cutting can be performed, but the difficulty and cost of laser debugging increases

Engineering Contradiction:

Improvecutting feasibilityVSAvoidlaser debugging complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The laser barrier layer serves as a mediator that simplifies the laser cutting process by providing a controlled interface between the laser beam and the metal electrode. This intermediary layer reduces the complexity of laser debugging by creating a more predictable and manageable cutting environment, thereby reducing both difficulty and cost.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If the contact film layer is made thin to facilitate cutting, then cutting can be performed, but the yield of display panels decreases

Engineering Contradiction:

Improvecutting feasibilityVSAvoiddisplay panel yield

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The laser barrier layer acts as a protective intermediary that prevents damage to the metal electrode during cutting operations. By providing this additional protection layer, the cutting process becomes more reliable and less prone to defects, thereby increasing the overall yield of display panels while maintaining cutting feasibility.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If a laser barrier layer is added to protect the metal electrode, then the risk of damaging the electrode decreases, but the device complexity increases

Engineering Contradiction:

Improvemetal electrode protectionVSAvoidlayer structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The laser barrier layer is a simple intermediary structure that provides effective protection without significantly complicating the overall device architecture. The layer can be deposited using standard thin-film deposition techniques and integrated into the existing multi-layer structure, adding minimal complexity while substantially improving electrode protection.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 laser barrier layer reduces the risk of damaging the underlying metal electrode, decreases the complexity and cost of laser debugging, and saves time in the half-cutting process while improving the yield of the display panels.

Implementation Method 1

made of materials like amorphous silicon or reflective materials, to prevent damage during laser cutting by absorbing or reflecting laser energy

Methodology Applied

Scientific EffectAbsorption (EM radiation): Absorption (EM radiation)

Implementation Method 2

made of materials like amorphous silicon or reflective materials, to prevent damage during laser cutting by absorbing or reflecting laser energy

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 3

outputting a laser beam to a surface of the protective film layer; and moving the laser beam along a target trajectory on a surface of the protective film layer

Methodology Applied

Scientific EffectLaser: Laser

Data Source

PatentUS11508949B2Display panel and display device

Publication Date: 2022.11.22 BEIJING BOE TECH DEV CO LTD

AI summary

The present disclosure provides a display panel and a display device including the same. The display panel comprises a transparent substrate and a display structure arranged on the transparent substrate, the display structure comprises a pixel unit array and a lead metal layer, a laser barrier layer is arranged on the lead metal layer, and an orthogonal projection of the laser barrier layer on the transparent substrate partially covers that of the lead metal layer on the transparent substrate.