OLED Display Metal Patterning Across Encapsulation Dams
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Solution Overview
Problem
The formation of dams in organic light emitting displays to prevent the flow of organic films during encapsulation can cause step differences, leading to issues with metal patterns remaining in undesired areas and affecting the display's surface uniformity and electrical connectivity.
Innovation Solution
A display device design that includes a dam structure with a first metal pattern not covering the dam area, using an insulating layer to address step differences, and a second metal pattern overlapping the dam area, ensuring proper electrical insulation and preventing residual films during metal pattern formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a dam is formed in the periphery of the organic light emitting device to prevent the flow of organic film, then the organic film can be contained within the encapsulation area, but a step difference is caused on the surface of the organic light emitting display
Solution Approach 1:
The patent introduces a second metal pattern on a different layer (above the insulating layer) that overlaps the dam area. This dimensional transition from the same-plane metal pattern to a multi-layer structure allows the metal pattern to extend over the dam without being affected by the step difference, thereby maintaining surface uniformity while preserving organic film containment.
2Reliability
If metal patterns are formed on the dam by a process using a photoresist pattern, then electrical connections can be established, but metal patterns remain in the corresponding area from which they have to be completely removed, causing a problem of remaining film
Solution Approach 1:
The patent divides the metal pattern formation into two separate segments: a first metal pattern formed on the same plane as the dam (avoiding the dam area to prevent remaining film), and a second metal pattern formed on a higher layer that overlaps the dam area. This segmentation allows electrical connections to be established through the contact hole while avoiding the remaining film problem by not forming metal directly on the dam surface.
Solution Approach 2:
The patent transitions the metal pattern from the same plane as the dam to a higher dimension by forming the second metal pattern above an insulating layer. This dimensional change allows the metal pattern to overlap the dam area and establish electrical connections through contact holes without creating remaining film issues on the dam surface.
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
Prevents residual films and maintains surface uniformity by insulating the dam area, ensuring reliable electrical connections and reducing manufacturing defects in the display device.
Implementation Method 1
The organic film has fluidity until before the curing process. Thus, the organic film having fluidity may flow out into an area to be provided with the encapsulation film.
Data Source
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AI summary
Disclosed is a display device which facilitates to prevent a remaining film for a process of forming a metal pattern, wherein the display device may include a substrate including a display area having pixels, and a non-display area having pads to surround the display area, a dam between the display area and the pads, an encapsulation film for covering the dam and the pixels in the display area, a first metal pattern disposed in the non-display area and patterned on the encapsulation film, an insulating layer provided on the first metal pattern, and a second metal pattern disposed in the non-display area and patterned on the insulating layer, wherein the first metal pattern is not provided in a dam area with the dam, and the second metal pattern is provided on the dam area while being in contact with the first metal pattern via a contact hole penetrating through the insulating layer.