OLED Encapsulation Structure for Crack-Resistant Barrier Layers
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Solution Overview
Problem
OLED displays are susceptible to water and oxygen ingress due to protrusion structures causing cracks in the barrier film, which shortens their service lifetime.
Innovation Solution
A display panel design with a first barrier layer embedding protrusion structures and a second barrier layer wrapping them, along with optional organic and inorganic layers, to enhance encapsulation and prevent cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a water and oxygen barrier film is formed on the OLED panel, then the encapsulation effectiveness is improved, but the barrier film is prone to cracks due to protrusion structures, reducing reliability
Solution Approach 1:
The barrier film is divided into multiple segments (first barrier layer and second barrier layer) that can independently accommodate protrusion structures. Each layer is discontinuous at different locations, preventing crack propagation through the entire barrier film while maintaining overall encapsulation effectiveness.
Solution Approach 2:
The patent transitions from a single-plane barrier film to a multi-layer three-dimensional barrier structure. The first and second barrier layers are positioned at different heights and locations, creating a立体 (three-dimensional) barrier that surrounds protrusion structures from multiple directions, preventing cracks while maintaining encapsulation.
2Reliability
If the barrier film is made continuous to improve encapsulation, then water and oxygen invasion is prevented, but protrusion structures cause cracks that compromise the barrier
Solution Approach 1:
The barrier film is segmented into multiple discontinuous layers rather than one continuous layer. The first barrier layer has discontinuities at first locations, the second barrier layer has discontinuities at second locations, and their projections do not completely overlap. This segmentation allows the barrier to accommodate protrusion structures without forming continuous cracks, maintaining both integrity and protection.
Solution Approach 2:
The patent uses a composite barrier structure combining multiple barrier layers with different spatial arrangements. This composite structure provides both mechanical strength to prevent cracking and continuous protection against water and oxygen by ensuring that discontinuities in one layer are compensated by coverage in other layers.
3Ease of manufacture
If protrusion structures are left on the OLED device, then the manufacturing process is simpler, but they create channels for water and oxygen invasion, shortening service lifetime
Solution Approach 1:
Instead of removing protrusion structures, the patent converts their presence into a beneficial design feature. The multi-layer barrier structure is specifically designed to accommodate protrusions, with discontinuities strategically positioned so that protrusions are surrounded rather than causing cracks. This approach maintains manufacturing simplicity while extending service lifetime by preventing water and oxygen invasion channels.
Data Source
AI summary
Embodiments of the present application provide an encapsulation structure, a display panel and a method of manufacturing the display panel. The encapsulation structure includes the barrier structure layer. In the barrier structure layer, the first barrier layer is adopted to fix the protrusion structure, and the second barrier layer is utilized to wrap the protrusion structure. The encapsulation structure provided by the embodiment of the present application implements the effective wrapping on the protrusion structure, solves the crack problem of the barrier layer caused by the protrusion structure, and thus enhances the service lifetime and reliability of the display panel.