Multilayer Dam Structure with Insulating Layer for Display Devices
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Solution Overview
Problem
Display devices face issues with peeling off of dams and overflow of organic materials during manufacturing, leading to adhesion problems and contamination in non-display areas.
Innovation Solution
A display device design featuring a multilayer dam structure with an inorganic insulating layer and vent holes, along with dummy pixels in the non-display area to enhance adhesion and prevent organic material overflow, using a combination of organic and inorganic materials to improve adhesive forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layer dam structure is used, then the manufacturing process is simple, but the dam peels off during the process
Solution Approach 1:
The dam structure is divided into multiple layers (first dam layer, second dam layer, third dam layer) with different materials and functions. Each layer serves a specific purpose: the first layer provides base adhesion, the second layer prevents organic material penetration, and the third layer provides top protection. This segmentation resolves the contradiction by maintaining manufacturing simplicity through a systematic multi-layer approach while significantly improving overall adhesion and reliability.
Solution Approach 2:
The patent employs composite materials in the dam structure, combining organic materials (first and third dam layers) with inorganic materials (second dam layer). This composite approach allows each material to contribute its strengths: organic materials provide flexibility and adhesion, while the inorganic layer provides barrier properties. The combination effectively prevents peeling and overflow without complicating the manufacturing process.
2Device complexity
If no insulating layer is used, then the structure is simple, but organic material overflows to the outer portion of the substrate
Solution Approach 1:
The insulating layer acts as an intermediary barrier between the organic material-containing layers and the substrate's outer portion. This intermediate layer specifically prevents organic material penetration and overflow to non-display areas, addressing the harmful overflow issue without requiring complete structural redesign. The insulating layer integrates smoothly into the existing dam structure, adding protection with minimal complexity increase.
3Object-generated harmful factors
If the dam structure is made thicker to prevent overflow, then overflow is reduced, but the manufacturing precision becomes more difficult
Solution Approach 1:
Instead of creating a single thick dam layer that would be difficult to manufacture with precise thickness control, the patent segments the protective function across multiple thinner layers. Each layer can be formed with standard thicknesses using conventional manufacturing processes, avoiding the need for precise control of a single thick layer. The cumulative effect of multiple layers provides the necessary overflow prevention while maintaining manufacturing precision.
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 effectively reduces the likelihood of dam peeling off and organic material overflow, enhancing the manufacturing process by improving adhesion and preventing contamination in non-display areas.
Implementation Method 1
an inorganic insulating layer, thereby increasing an adhesive force of the dam
Implementation Method 2
the insulating layer defines vent holes penetrating the insulating layer in the non-display area
Implementation Method 3
at least one dam in the non-display area, surrounding the display area, and including a lower dam layer above the substrate, an intermediate dam layer above the lower dam layer, and an upper dam layer covering the lower dam layer and the intermediate dam layer
Data Source
AI summary
A display device is provided. The display device includes a substrate including a display area and a non-display area, an insulating layer above the substrate, and in the display area and the non-display area, and at least one dam in the non-display area, surrounding the display area, and including a lower dam layer above the substrate, an intermediate dam layer above the lower dam layer, and an upper dam layer covering the lower dam layer and the intermediate dam layer, wherein the insulating layer is between the intermediate dam layer and the upper dam layer.