Mother Substrate Partition for OLED Moisture Containment

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Solution Overview

Problem

The manufacturing process of display devices with organic light-emitting diodes (OLEDs) faces challenges in improving yield due to issues with moisture ingress and adhesion failures in the margin areas of mother substrates, leading to contamination and reduced efficiency.

Innovation Solution

Incorporating a partition with an overhang shape in the margin areas of the mother substrate, comprising a lower and upper portion with protruding end portions, which helps to contain moisture ingress and maintain adhesion between organic and inorganic layers, thereby preventing exfoliation and contamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the margin area of the mother substrate is left without partitions, then the manufacturing process is simpler, but moisture ingress causes adhesion failure and exfoliation of organic layers

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidadhesion between organic and inorganic layers

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The margin area is divided into multiple smaller regions by introducing partitions, creating isolated closed areas that prevent moisture from spreading across the entire margin area, thus protecting the organic layers in each segmented region

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Partitions act as intermediary barrier structures between the moisture environment and the organic layers, physically blocking moisture ingress and preventing direct contact between moisture and the organic-inorganic layer interface

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If partitions are added to the margin area to prevent moisture ingress, then adhesion reliability improves, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improveadhesion between organic and inorganic layersVSAvoidpartition structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Partitions are introduced only in the margin area where moisture ingress is a problem, while the display area maintains its original simple structure, thus applying protection locally without unnecessarily complicating the entire device

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Rather than attempting to protect the entire substrate uniformly, partitions are applied partially only to the margin areas where moisture contamination occurs, providing sufficient protection with minimal added complexity

Inventive Principle:

Principle #16Partial or excessive action

3Reliability

If partitions with overhang shapes are used to contain moisture, then exfoliation prevention improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improveprevention of organic layer exfoliationVSAvoidpartition protrusion dimensional accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The overhang shape is designed into the partition structure in advance during the patterning process, creating a built-in mechanical interlock feature that prevents exfoliation before moisture can cause damage, rather than attempting to correct exfoliation after it occurs

Inventive Principle:

Principle #10Preliminary action

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 configuration enhances the manufacturing yield by limiting the expansion of exfoliation portions and maintaining the integrity of the organic layers, reducing contamination and improving the overall efficiency of the display device production process.

Implementation Method 1

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Implementation Method 2

which helps to contain moisture ingress and maintain adhesion between organic and inorganic layers, thereby preventing exfoliation and contamination

Methodology Applied

Scientific EffectGeometric constraint: Geometry

Data Source

PatentUS20240260324A1Mother substrate for display device and display device

Publication Date: 2024.08.01 MAGNOLIA WHITE CORP

AI summary

According to one embodiment, a mother substrate for a display device includes a plurality of panel portions each of which includes a display area in which a plurality of display elements are provided, a margin area around the panel portions, and a first partition provided in the margin area. Each of the display elements includes a lower electrode, an upper electrode which faces the lower electrode, and an organic layer which is provided between the lower electrode and the upper electrode. The first partition includes a first lower portion and a first upper portion including an end portion which protrudes from a side surface of the first lower portion.