OLED Screen Frameless Display via Mirror Layer and Flexible Substrate
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Solution Overview
Problem
Current organic light emitting diode (OLED) screens with curved designs face challenges in achieving a frameless display effect due to the rigidity and high cost of 3D glass, which results in a low yield rate and susceptibility to breakage when dropped, with the left and right frames still maintaining a width of approximately 1 mm.
Innovation Solution
An OLED screen structure comprising a back plate, polyimide layer, array layer, organic light emitting diode layer, thin film encapsulation layer, polarizer, and cover plate, with a mirror layer between the encapsulation layer and polarizer, and a thickened cathode on the pixel definition layer in the peripheral area, allowing for bending angles that enhance the mirror effect and reduce frame visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If 3D glass is used to achieve curved screen effect, then the screen can be bent to shorten frame width, but the yield rate is low and cost is high
Solution Approach 1:
The patent replaces rigid 3D glass with flexible thin film structures including a polyimide layer, multiple organic light emitting diode layers, and encapsulation layers. These thin films enable the screen to be bent into curved shapes while maintaining structural integrity, achieving the curved screen effect without the high cost and low yield rate associated with 3D glass manufacturing
Solution Approach 2:
The patent employs a composite structure consisting of multiple functional layers: polyimide layer for flexibility, organic light emitting diode layers for light emission, encapsulation layers for protection, and electrode layers for electrical connection. This composite material approach enables the screen to achieve both the desired curved shape and functional performance while improving manufacturing yield and reducing cost
2Length of moving object
If 3D glass is used for curved screen, then frame width is reduced, but the screen is easily broken when dropped
Solution Approach 1:
The flexible thin film structure replaces brittle 3D glass, enabling the screen to bend without breaking. The polyimide layer and encapsulation layers provide flexibility and impact resistance, allowing the screen to withstand drops and mechanical stress while maintaining the curved shape and reduced frame width
Solution Approach 2:
The encapsulation layers and polyimide layer act as protective cushioning structures that absorb impact energy before it reaches the sensitive OLED components. This beforehand cushioning protects the screen from breakage during drops while maintaining the thin, curved profile
3Shape
If mirror layer is exposed in peripheral area, then frameless effect is achieved, but peripheral traces may become visible
Solution Approach 1:
The patent applies different properties to different areas: the mirror layer is exposed in the peripheral area to achieve the frameless effect by reflecting ambient light, while the polarizer is positioned to cover areas where traces might be visible. This local differentiation of optical properties allows the screen to simultaneously achieve the frameless aesthetic and hide peripheral traces
Solution Approach 2:
The polarizer acts as an intermediary element between the mirror layer and the external environment. It selectively controls the polarization of light to prevent peripheral traces from being visible while allowing the mirror layer to provide the frameless effect in appropriate areas
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
The solution enables a frameless display effect by transmitting light from the OLED layer and reflecting external light when not in use, preventing peripheral area traces from being visible, while the thickened cathode and bending layers improve the mirror effect and structural rigidity.
Implementation Method 1
the mirror layer can reflect the external light to achieve the display effect of the mirror-type organic light emitting diode screen
Implementation Method 2
the light emitted by the organic light emitting diode layer can be transmitted out of the peripheral area to achieve a frameless display effect
Data Source
AI summary
Provided are an OLED screen and a manufacturing method thereof. The OLED screen has a display area and a peripheral area located on a left side and a right side of the display area. The OLED screen comprises: a back plate, a polyimide layer, an array layer, an OLED layer, a thin film encapsulation layer, a polarizer and a cover plate stacked in order; a mirror layer is disposed between the thin film encapsulation layer and the polarizer, and at least a portion of the mirror layer in the peripheral area is not covered with the polarizer; a portion of the cover plate in the peripheral area is not covered with ink. When the organic light emitting diode screen is lit, the light emitted by the organic light emitting diode layer can be transmitted out of the peripheral area to achieve a frameless display effect.