OLED Dam Unit Segmentation for Packaging Overflow Control
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Solution Overview
Problem
Current OLED display devices experience organic packaging material overflow due to machine errors and substrate differences during the coating process, leading to lateral erosion from outside water and oxygen, which affects their longevity.
Innovation Solution
The OLED display device incorporates a dam unit with a flattening layer, pixel isolation layer, and pixel support layer, along with a film packaging layer comprising inorganic and organic layers, to prevent lateral erosion. The dam unit is designed with specific width and height configurations to manage the packaging materials effectively, using materials like silicon nitride, silicon dioxide, and acrylic to enhance protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the width of dam walls is increased to prevent organic packaging material overflow, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The dam wall structure is divided into multiple segments with different widths: a first dam wall portion with width W1 and a second dam wall portion with width W2 (where W1 < W2). This segmentation allows the structure to prevent overflow effectively while maintaining reasonable complexity by using standardized width ratios.
Solution Approach 2:
Different portions of the dam wall are assigned different local qualities (widths) based on their functional requirements. The second dam wall portion has a larger width to provide overflow prevention, while the first dam wall portion has a smaller width to reduce complexity. The width ratio W1:W2 is controlled within 1:1.5 to optimize this local differentiation.
2Reliability
If the organic packaging layer thickness is increased to improve coverage, then reliability is improved, but manufacturing precision deteriorates due to machine error and substrate differences
Solution Approach 1:
The packaging structure uses a composite of organic and inorganic materials. The inorganic packaging layer (first and second inorganic packaging layers) provides reliable water and oxygen barrier function, while the organic packaging layer fills pinholes and provides stress buffering. This composite approach ensures reliability without requiring excessive organic material thickness, thus maintaining manufacturing precision.
Solution Approach 2:
The inorganic packaging layers are deposited beforehand to provide a preliminary barrier against water and oxygen. This preliminary action ensures that even if the organic packaging layer has variations due to machine error or substrate differences, the underlying inorganic layers already provide reliable protection, compensating for manufacturing precision issues.
3Reliability
If the dam wall width is increased to prevent lateral erosion, then reliability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The dam wall is segmented into two portions with widths W1 and W2, where the ratio W1:W2 is controlled within 1:1.5. This segmentation allows the structure to provide effective lateral erosion prevention through the wider second portion while the narrower first portion facilitates easier manufacturing and coating application.
Solution Approach 2:
The dam wall width parameters are optimized by controlling the ratio W1:W2 within 1:1.5. This parameter change ensures that the dam wall is wide enough to prevent lateral erosion (improving reliability) but not so wide as to create significant manufacturing difficulties (maintaining ease of manufacture).
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 configuration effectively prevents lateral erosion of water and oxygen, enabling the production of OLED devices with narrow bezels by ensuring the organic packaging layer's height is controlled within specific limits, thereby extending the device's lifespan.
Implementation Method 1
The inorganic layer is mainly used to cut off water and oxygen
Implementation Method 2
organic layer is used to buffer stress and fill some pinholes in inorganic layer to enhance the channel cutting off water and oxygen function
Data Source
AI summary
The present invention provides an OLED display device, comprising: an OLED display panel, the OLED display panel comprising a display area and non-display areas in the both-ends edges of the display area; a dam unit and a film packaging layer. A part of the film packaging layer corresponding to the display area is disposed on the surface of the OLED display panel; another part of the film packaging layer corresponding to the non-display area is disposed on the surface of the dam unit; wherein, the dam unit comprises a flattening layer, a pixel isolation layer and a pixel support layer stacked-up together.