OLED Display Panel Corner Crack Prevention
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Solution Overview
Problem
Conventional display device manufacturing methods, such as sawing and grinding, often result in damage to display panels, leading to cracks and permeation of moisture and oxygen, which can compromise the integrity and performance of high-resolution OLED displays used in wearable devices like HMDs and AR glasses.
Innovation Solution
Incorporating a crack prevention region with a double line shape and a permeation prevention region in the corners of the display panel, utilizing metal layers at the same layer as the light-emitting element backplane, to protect against damage during processing and prevent moisture and oxygen ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional sawing and grinding processes are used to manufacture display panels, then manufacturing efficiency is improved, but display panels suffer damage including cracks and moisture/oxygen permeation
Solution Approach 1:
The patent applies preliminary action by forming a crack prevention region with an extended metal layer structure before the sawing and grinding processes. This pre-formed structural reinforcement is designed to withstand the mechanical stresses of subsequent manufacturing steps, preventing cracks from developing during cutting and corner rounding operations.
Solution Approach 2:
The patent employs composite materials by creating a multi-layer metal structure consisting of different metal layers with potentially different properties. The extended metal layer in the crack prevention region combines structural support functions with barrier properties, creating a composite material system that simultaneously provides mechanical strength and protection against moisture and oxygen permeation.
2Ease of manufacture
If conventional manufacturing processes are used, then production cost is reduced, but display panels become vulnerable to cracks and permeation damage
Solution Approach 1:
The patent merges multiple protective functions into a single integrated structure. The extended metal layer simultaneously serves as a crack prevention mechanism, a barrier against moisture and oxygen permeation, and a structural reinforcement element. This consolidation eliminates the need for separate protective layers or post-processing repairs, maintaining ease of manufacture while improving display panel quality.
3Device complexity
If corner regions are left without additional protection, then device complexity is minimized, but cracks and moisture/oxygen permeation occur during processing
Solution Approach 1:
The patent applies local quality by concentrating the extended metal layer structure specifically at the corner regions of the display panel, where cracks are most likely to initiate during sawing and grinding. Rather than uniformly reinforcing the entire panel, the crack prevention region is locally applied to high-stress corner areas, providing targeted protection with minimal additional complexity.
Data Source
AI summary
According to one or more embodiments, a display device may include a display panel including a display panel having a display area in which a light-emitting element is located, and a non-display area outside the display area in plan view and including a permeation prevention region outside an encapsulation area, and a crack prevention region outside the permeation prevention region and in a double line shape at at least one corner of the display panel.