OLED Display Spacer Design for Mask Contact Stress Mitigation
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Solution Overview
Problem
During the manufacturing process of OLED displays, the contact between the display device and the mask can cause damage due to the direct contact and subsequent stress concentration on the partition wall spacers, leading to delamination issues.
Innovation Solution
The implementation of partition wall spacers and spacers in the non-display area with adjusted heights and densities to minimize the contact area with the mask, using the same material and layer structure as the partition walls, and incorporating a dummy electrode in the spacers to match the transistor layer structure, thereby reducing stress concentration and facilitating mask separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the mask contacts the display device during positioning, then the manufacturing process can proceed, but the partition wall spacers are damaged due to stress concentration
Solution Approach 1:
The patent introduces a non-display area spacer as an intermediary element between the mask and the partition wall spacers. This spacer absorbs the contact stress during mask positioning, preventing direct transmission of force to the partition wall spacers. The intermediary spacer is specifically designed to be positioned in the non-display area where it can interface with the mask without compromising the display area structures.
Solution Approach 2:
The patent implements a cushioning structure by designing the non-display area spacer with specific height and material properties that allow it to absorb impact stress before it reaches the partition wall spacers. This beforehand cushioning is built into the device structure, ensuring that when mask contact occurs during positioning, the stress is already mitigated by the time it could affect the partition wall spacers.
2Manufacturing precision
If the partition wall spacers have high height to define emission areas, then the display performance is improved, but the stress concentration during mask contact increases causing delamination
Solution Approach 1:
The patent segments the spacer functionality into two distinct locations: partition wall spacers in the display area that maintain high height for precise emission area definition, and non-display area spacers that serve as stress-absorbing elements. This segmentation allows each spacer type to be optimized for its specific function without compromise.
Solution Approach 2:
The patent applies local quality by giving different heights and positions to spacers based on their location and function. Partition wall spacers in the display area maintain high height for precise emission area definition, while non-display area spacers are positioned to absorb stress. Each location has tailored spacer properties suited to its specific requirements.
3Reliability
If spacers are added in the non-display area to prevent damage, then the partition wall spacer integrity is improved, but the device structure becomes more complex
Solution Approach 1:
The non-display area spacer serves multiple functions: it acts as a stress-absorbing element during mask positioning, defines the boundary between display and non-display areas, and provides structural support. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity while achieving protection of partition wall spacers.
Data Source
AI summary
A display device includes a substrate having a display area and a non-display area located at an outer periphery of the display area; a transistor layer disposed on the substrate; a plurality of partition walls disposed on the transistor layer in the display area; a light emitting element disposed between the partition walls; and a spacer configured to be disposed in the non-display area of the substrate, wherein the spacer may include a spacer body disposed on the same layer as the partition walls and on at least a portion of the transistor layer.