OLED Encapsulation Dam Structure Using Single Mask Plate
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Solution Overview
Problem
The existing encapsulation methods for OLED display devices, such as substrate encapsulation and thin film encapsulation, require multiple mask plates and frequent replacements, increasing production costs and complexity, while failing to effectively prevent water vapor and oxygen ingress, which shortens the service life of OLEDs.
Innovation Solution
A method involving a single mask plate to form a dam in the peripheral region of the display substrate, upon which multiple thin film encapsulation layers are formed, enveloping the dam to delay the ingress of water vapor and oxygen, thereby simplifying the encapsulation process and extending the OLED's service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple mask plates are used to form thin film encapsulation layers with different sizes, then water vapor and oxygen penetration is prevented, but production cost and process complexity increase
Solution Approach 1:
The patent merges multiple encapsulation functions into a single dam structure. The dam is designed with a body portion and a protruding portion that work together to provide both the encapsulation barrier and the edge coverage function that previously required multiple separate mask plates. This consolidation reduces process complexity while maintaining the same level of protection against water vapor and oxygen penetration.
Solution Approach 2:
The dam structure is segmented into distinct functional portions: a body portion that provides the main encapsulation barrier and a protruding portion that extends to cover edges. This segmentation allows each portion to perform its specific function effectively, with the protruding portion preventing edge penetration and the body portion providing the primary barrier, thereby achieving comprehensive protection with a single structure.
2Reliability
If multiple mask plates are used to form thin film encapsulation layers, then edge protection is improved, but production cost increases
Solution Approach 1:
The patent combines the edge protection function and the main encapsulation function into a single dam structure formed by one mask plate. The protruding portion of the dam specifically addresses edge protection needs, while the body portion provides the main barrier, eliminating the need for multiple mask plates and reducing production costs associated with frequent mask plate replacement.
Solution Approach 2:
The dam structure is designed in advance with the protruding portion that pre-configures the edge protection capability. By incorporating the edge coverage function into the dam's geometry before the encapsulation process begins, the patent eliminates the need for additional mask plates during manufacturing, thereby reducing production costs while maintaining reliable edge protection.
3Length of stationary object
If thin film encapsulation layers are formed closer to the OLED, then device thickness is reduced, but water vapor and oxygen permeation increases
Solution Approach 1:
The patent addresses the permeation issue by adding a dimensional element - the protruding portion of the dam that extends outward from the body portion. This dimensional extension creates a physical barrier that increases the effective distance water vapor and oxygen must travel to reach the OLED edges, thereby reducing permeation without requiring the main encapsulation layers to be thicker or positioned farther away.
Data Source
AI summary
Embodiments of the disclosure provide an Organic Light-Emitting Diode (OLED) display device and an encapsulation method thereof. The encapsulation method of the OLED display device comprises: providing a display substrate, the display substrate having a display region and a peripheral region provided outside the display region; forming a dam in the peripheral region of the display substrate; and forming a plurality of thin film encapsulation layers on the display substrate by using a single mask plate, wherein the plurality of thin film encapsulation layers envelop the dam therein.