Light-Emitting Device Sealing Layer Removal via Cover Layer Protrusion
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Solution Overview
Problem
The existing methods for forming sealing layers in light-emitting devices often cover terminals, making it difficult to remove the sealing layer without damaging the device.
Innovation Solution
A light-emitting device configuration that includes a substrate, a light-emitting unit, terminals connected to the unit, a sealing layer that does not cover the terminals, and a cover layer made of a different material with protrusions extending beyond the sealing layer, allowing for the removal of the sealing layer without affecting the terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealing layer is formed using a vapor phase method to seal the light-emitting unit, then the sealing performance is improved, but the terminal becomes covered and difficult to access
Solution Approach 1:
The sealing structure is divided into two distinct layers: a sealing layer that provides moisture and oxygen barrier protection, and a cover layer that protects the sealing layer while allowing terminal access. This segmentation allows each layer to fulfill its specific function without interfering with terminal accessibility.
Solution Approach 2:
The cover layer is designed to be removable or separable from the sealing layer, allowing the sealing layer to be accessed and removed if needed without damaging the terminal. This extraction approach enables maintenance and repair operations on the sealing structure while preserving terminal functionality.
2Reliability
If a sealing layer is formed over the terminal, then the light-emitting unit is fully sealed, but the sealing layer needs to be removed which complicates the manufacturing process
Solution Approach 1:
The cover layer is formed first as a preliminary structure, followed by the sealing layer. This sequence allows the sealing layer to be formed completely over the light-emitting unit including the terminal area, while the pre-formed cover layer serves as a template or mask that defines where the sealing layer should be removed, simplifying the subsequent removal process.
Solution Approach 2:
The cover layer acts as an intermediary structure between the terminal and the sealing layer. It provides a clear boundary or interface that facilitates the selective removal of the sealing layer from the terminal area without requiring complex removal processes or risking damage to the terminal.
3Ease of operation
If the sealing layer is removed from the terminal, then the terminal becomes accessible, but the structural integrity may be compromised
Solution Approach 1:
The cover structure is segmented into the cover layer and sealing layer, where the cover layer remains in place to maintain structural integrity while the sealing layer is selectively removed from the terminal area. This segmentation allows terminal accessibility without compromising the overall structural strength of the light-emitting device.
Solution Approach 2:
The cover layer serves as a protective cushion or support structure that remains in place after the sealing layer is removed from the terminal. This pre-existing cover layer prevents structural collapse or damage to the terminal area, maintaining the overall integrity of the device while allowing terminal access.
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
Enables the easy removal of the sealing layer from the terminals while maintaining the integrity of the light-emitting device, preventing damage to the terminals and ensuring the device's functionality.
Implementation Method 1
a cover layer which is formed over the sealing layer, and is formed of a material different from that of the sealing layer
Data Source
AI summary
A light-emitting unit (140) is formed over a first surface (102) of a substrate (100). A first terminal (112) and a second terminal (132) are formed on the first surface (102) of the substrate (100), and are electrically connected to the light-emitting unit (140). A sealing layer (200) is formed over the first surface (102) of the substrate (100), and seals the light-emitting unit (140). In addition, the sealing layer (200) does not cover the first terminal (112) and the second terminal (132). A cover layer (210) is formed over the sealing layer (200), and is formed of a material different from that of the cover layer (210). In at least a portion of a region located next to the first terminal (112) and a region located next to the second terminal (132), a portion of an end of the cover layer (210) protrudes from the sealing layer (200).