Multi-Recess OLED Module Hole Sealing Against Moisture Ingress
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Solution Overview
Problem
Organic light-emitting display devices are vulnerable to moisture and oxygen, leading to reliability and lifespan issues due to external contamination.
Innovation Solution
A display panel design featuring a base substrate with a module hole and recesses, where a sealing layer with inorganic and organic films is used to block moisture and oxygen, enhancing mechanical strength and preventing crack formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a module hole is provided in the base substrate for component mounting, then ease of manufacture and device functionality are improved, but mechanical strength and reliability deteriorate due to structural weakness and vulnerability to moisture/oxygen
Solution Approach 1:
The base substrate is segmented into multiple recesses (first recess surrounding the module hole, second recess surrounding the first recess) that create distinct functional zones. This segmentation allows the module hole to be isolated from the edges, maintaining structural integrity while enabling component mounting in the central region.
Solution Approach 2:
The patent implements a nested recess structure where the first recess is surrounded by the second recess, creating concentric protective zones around the module hole. This nested configuration reinforces the area around the hole without preventing component installation, effectively combining structural strengthening with manufacturing accessibility.
2Adaptability or versatility
If a module hole is provided in the base substrate, then device functionality is improved, but reliability deteriorates due to introduction of moisture and oxygen
Solution Approach 1:
The sealing layer is formed in advance to cover the module hole and fill the recesses before any moisture or oxygen contamination can occur. This preliminary sealing action prevents contaminants from entering through the hole, maintaining reliability while preserving the functionality enabled by the hole.
Solution Approach 2:
The sealing layer acts as an intermediary barrier between the module hole (which enables functionality) and the external environment (moisture and oxygen). This mediator allows the hole to serve its purpose while blocking harmful contaminants, resolving the contradiction between functionality and reliability.
3Device complexity
If the base substrate structure is simplified without recesses, then manufacturing complexity is reduced, but mechanical strength and contaminant protection deteriorate
Solution Approach 1:
The patent uses a sealing layer (thin film structure) that conforms to the complex recess geometry. This flexible sealing approach protects the intricate multi-recess structure without requiring additional rigid protective components, maintaining manufacturing feasibility while providing the needed strength and protection.
4Reliability
If a sealing layer with multiple films is used to block moisture and oxygen, then reliability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The sealing layer structure is optimized locally: the organic film is selectively filled only in the second recess (outer recess) while leaving the first recess (inner recess) open. This local differentiation provides enhanced protection at the outer boundary while maintaining accessibility and simplicity in the inner region, reducing overall manufacturing complexity.
Data Source
AI summary
A display device includes: a base substrate including a front surface and a rear surface, and including a display region and a peripheral region adjacent to the display region in a plan view; an organic light-emitting element on the display region; and a sealing layer on the organic light-emitting element. The base substrate includes: a module hole in the display region, and passing through the front surface and the rear surface; a first recess at the display region and recessed from the front surface, the first recess surrounding the module hole in the plan view; and a second recess at the display region and recessed from the front surface, the second recess surrounding the first recess in the plan view. The first recess and the second recess have different widths from each other in a direction parallel to the front surface.