Non-Orthogonal Partition for Uniform Resist Coverage

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Solution Overview

Problem

The manufacturing process of OLED display devices faces challenges in maintaining reliability due to issues such as the formation of undesired cavities and non-uniformities in the resist layer, which can lead to defects and reduced performance.

Innovation Solution

A mother substrate and display device design featuring a partition structure with a non-orthogonal shape that prevents the resist layer from being dammed up, ensuring uniform coverage and preventing the formation of cavities, along with a manufacturing method that includes forming inorganic insulating layers and partitions to maintain reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a partition structure with non-orthogonal shape is used, then the resist layer coverage uniformity is improved and cavity formation is prevented, but the manufacturing process complexity increases

Engineering Contradiction:
Improveresist layer coverage uniformityVSAvoidpartition structure complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The partition is designed with a non-orthogonal shape where the first side is inclined relative to the second side, creating an asymmetric structure. This asymmetry prevents the resist layer from being dammed up during application, ensuring uniform coverage and preventing cavity formation while maintaining manufacturing feasibility

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The partition is divided into multiple sides (first side, second side, third side, fourth side) with specific geometric relationships. The first and second sides are parallel, while the third and fourth sides are parallel to each other but inclined relative to the first and second sides, creating a segmented geometric structure that achieves uniform resist coverage

Inventive Principle:
Principle #1Segmentation

2Reliability

If a partition structure with non-orthogonal shape is used, then the reliability is improved by preventing defect formation, but the manufacturing process steps increase

Engineering Contradiction:
Improvedisplay device reliabilityVSAvoidmanufacturing process simplicity
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The partition structure is formed in advance with the specific non-orthogonal geometry before the resist layer application. This preliminary formation of the inclined partition structure prevents cavity and defect formation during subsequent manufacturing steps, ensuring reliability without requiring additional corrective processes

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The non-orthogonal shape of the partition, which might be considered a geometric complexity, is actually beneficial as it prevents the resist layer from being dammed up. The inclined sides create a geometry that naturally allows uniform resist flow and prevents cavity formation, converting what could be seen as a manufacturing complexity into a reliability-enhancing feature

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS20240315085A1Mother substrate for display device, display device and manufacturing method of display device
Publication Date: 2024.09.19 MAGNOLIA WHITE CORP
  • US20240315085A1 patent drawing
  • US20240315085A1 patent drawing
  • US20240315085A1 patent drawing

AI summary

According to one embodiment, a mother substrate includes a substrate including a linear first side, a plurality of panel portions, a margin portion provided on an external side relative to the panel portions, and a first partition including a first lower portion provided in the margin portion, and a first upper portion provided on the first lower portion and protruding from a side surface of the first lower portion. The first partition has a shape which is not orthogonal to an extension direction of the first side.