OLED Boss Portion Design for Water Vapor Ingress Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current full-screen technologies in mobile phones face issues such as water vapor ingress due to exposed organic electro-luminescent and cathode layers, and require costly laser ablation processes for opening creation, which complicates manufacturing.
Innovation Solution
An organic light-emitting display device design featuring a substrate with a boss portion made of photoresist material, where the organic light-emitting and electrode layers are disconnected at the boss portion, and an encapsulating structure that includes inorganic and organic layers to prevent water vapor ingress, eliminating the need for laser ablation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser ablation process is used to remove organic electro-luminescent material layer and cathode layer at the opening, then the opening can be formed, but the manufacturing cost increases due to addition of laser equipment
Solution Approach 1:
The photoresist boss portion is formed in advance during the standard photolithography process, creating a predetermined discontinuation structure that will later prevent water vapor ingress. This preliminary formation of the protective structure eliminates the need for subsequent laser ablation steps, reducing both equipment requirements and manufacturing costs while maintaining the necessary opening structure
Solution Approach 2:
The photoresist boss portion serves as an intermediary structure that fulfills multiple functions: it acts as a placeholder during manufacturing, creates the necessary discontinuation of electrode layers to prevent water vapor paths, and can be removed or retained as needed. This intermediary structure replaces the need for complex laser ablation equipment while achieving the same protective effect
2Ease of manufacture
If organic electro-luminescent material layer or cathode layer is exposed at the opening, then the display device can be manufactured, but water vapor easily enters the display device causing display failure
Solution Approach 1:
The photoresist boss portion is selectively formed only at the opening area, creating a localized discontinuation of the organic electro-luminescent material layer and cathode layer. This local modification prevents water vapor ingress specifically at the opening without affecting other areas of the display device, maintaining manufacturing simplicity while improving waterproof performance at the critical location
Solution Approach 2:
The boss portion is formed in advance to create a physical barrier that prevents water vapor from reaching the electrode layers. By anticipating the water vapor ingress problem and pre-forming the protective structure during normal photolithography, the design proactively prevents display failure without requiring complex additional manufacturing steps
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
This design enhances the encapsulating reliability of the display device by preventing water vapor and oxygen invasion, simplifies the manufacturing process, and reduces costs by eliminating the need for laser processing equipment.
Implementation Method 1
the boss portion includes a photoresist material... an encapsulating structure that includes inorganic and organic layers to prevent water vapor ingress
Data Source
AI summary
An organic light-emitting display device and a manufacturing method thereof are disclosed. The display device includes a substrate including a first area, a second area and a third area, the second area being located between the first area and the third area; a plurality of pixels on the substrate, the plurality of pixels being located in the third area; a boss portion on the substrate, the boss portion being located in the second area; and an opening located in the first area and surrounded by the plurality of pixels. Each of the pixels includes a first electrode layer, an organic light-emitting layer, and a second electrode layer which are sequentially arranged in a direction away from the substrate. At least one of the organic light-emitting layer and the second electrode layer extends toward the opening and is disconnected at the boss portion. The boss portion includes a photoresist material.