OLED Barrier Trench Design for Organic Layer Overflow Control
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Solution Overview
Problem
OLED display panels face issues with organic layer overflow from complex corner regions in thin film packaging structures, leading to oxygen and moisture invasion, which reduces the device's lifespan due to inadequate sealing.
Innovation Solution
A trench is strategically placed in the straight-edge region between two barriers on the OLED display panel's TFT array substrate, creating a height difference between the straight-edge and corner regions, allowing overflowed organic layers to distribute to the lower straight-edge area, thereby reducing the risk of external leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single barrier with complex corner regions is used to define the boundary of organic layers, then the barrier can surround the display region, but the organic layers may overflow from the corner regions, resulting in invasion of oxygen and moisture
Solution Approach 1:
The single barrier is divided into two separate barriers (first barrier and second barrier) with different functions. The first barrier defines the boundary of the organic layers, while the second barrier provides additional protection and contains the organic layers through a trench structure, preventing overflow at corner regions.
Solution Approach 2:
A trench structure is introduced in the straight-edge region between the first and second barriers, creating a height difference that forms a three-dimensional containment structure. This additional dimensional feature effectively prevents organic layer overflow without requiring complex corner region modifications.
2Shape
If the barrier has a closed ring structure with straight-edge region and corner region, then the boundary can be clearly defined, but the complex shape of corner regions causes organic layer overflow
Solution Approach 1:
Different regions of the barrier structure are given different properties: the first barrier has a closed ring structure for defining boundaries, while the second barrier includes a trench in the straight-edge region to provide enhanced containment. Each region is optimized for its specific function rather than applying a uniform structure throughout.
3Manufacturing precision
If dams are formed in peripheral areas to confine organic layers, then the organic layers can be restricted to certain regions, but overflow may still occur at corner regions with complex profiles
Solution Approach 1:
The confinement function is segmented between two barriers: the first barrier provides the primary boundary definition, while the second barrier with its trench structure provides secondary containment specifically targeted at preventing corner region overflow.
Solution Approach 2:
The trench structure is formed in advance in the straight-edge region between the barriers, creating a height difference that proactively prevents organic layer overflow before it can reach the corner regions, rather than attempting to modify the corner regions themselves.
Data Source
AI summary
An OLED display panel and manufacturing method thereof. The OLED display panel includes a TFT array substrate, organic light emitting units, a first barrier, a second barrier, a trench, and a thin film packaging structure. The first barrier and the second barrier are disposed in a non-display region. The trench is formed corresponding to the position of a gap between the first barrier and the second barrier. The trench is disposed in an insulating layer stacked structure of the TFT array substrate. The thin film packaging structure covers above elements. The trench is disposed in a straight-edge region and a height difference is formed between the straight-edge region and a corner region. This can efficiently lower the risk of overflow from the corner region to the outside for an organic layer of the thin film packaging structure.