OLED Encapsulation Organic Layer Height Control
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Solution Overview
Problem
Conventional OLED displays face high failure rates due to the fluidity of encapsulating materials during packaging, which can cause damage to subsequent film layers, particularly at the corners of the encapsulation film, leading to suboptimal performance and reliability issues.
Innovation Solution
A display panel design with a thin-film encapsulation layer that includes organic layers extending to the non-display region, where the height of the organic layer at the corner is greater than at the side, reducing height loss and preventing damage to subsequent film layers through controlled inkjet printing and strategic placement of blocking walls and filling portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thin-film encapsulation technology is used to protect light-emitting devices, then protection effect is improved, but subsequent film layers are easily broken at boundaries due to material fluidity
Solution Approach 1:
The patent applies different heights of the organic layer at different locations: the first height at the boundary area and the second height at the corner area. This local differentiation ensures adequate protection at boundaries while preventing material overflow and subsequent film layer breakage at corners, resolving the contradiction between protection effect and film layer integrity.
Solution Approach 2:
The patent performs preliminary action by controlling the height of the organic layer during the encapsulation process itself. By pre-establishing the correct height distribution before subsequent film layers are deposited, the patent prevents future film layer breakage while maintaining protection effects.
2Reliability
If encapsulating material is applied to cover light-emitting devices, then encapsulation is achieved, but height loss occurs at corners due to material fluidity
Solution Approach 1:
The patent addresses height loss by applying local quality differentiation: the organic layer is formed with a first height at boundary areas and a greater second height at corner areas. This compensates for the natural height loss at corners due to material fluidity while maintaining proper encapsulation effectiveness.
3Ease of manufacture
If uniform height of organic layer is maintained, then manufacturing simplicity is preserved, but corner areas experience height loss and film layer breakage
Solution Approach 1:
The patent resolves this contradiction by implementing local quality with two distinct heights: the first height for boundary areas and the second (greater) height for corner areas. This targeted approach improves film layer stability at corners without significantly complicating the overall manufacturing process.
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
This design effectively reduces the risk of film layer breakage, enhances the reliability and pass rate of display panels, and improves production efficiency by minimizing height loss and optimizing the encapsulation process.
Implementation Method 1
by controlling a printing amount of the organic material in the inkjet printing, the height loss of the organic material at the corner of the encapsulation film layer may be reduced
Implementation Method 2
the encapsulating material may have certain fluidity before solidification during the packaging process
Data Source
AI summary
Display panel and display device are provided. The display panel includes: a display region and a non-display region surrounding the display region. The display region includes a light-emitting layer above a substrate, and a thin-film encapsulation layer is on a side of the light-emitting layer away from the substrate; the thin-film encapsulation layer includes at least one organic layer extending to the non-display region; and in a direction perpendicular to a plane of the substrate, a height of the at least one organic layer at a corner of the display region is greater than a height of the at least one organic layer at a side of the display region.