OLED Panel Second Pixel Definition Layer Cutting Protection
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Solution Overview
Problem
The existing flexible encapsulation technology for OLED panels requires frequent changes of metal masks, reducing production efficiency and allowing water and oxygen to invade the panel, thereby shortening its service life.
Innovation Solution
A second pixel definition layer with inverted trapezoidal structures is introduced between the first pixel definition layer and the encapsulation layer, made from materials like epoxy resin, polyimide, or polymethyl methacrylate, which prevents external water and oxygen from entering the panel during cutting, eliminating the need for frequent metal mask changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing flexible encapsulation technology is used, then the OLED panel can be encapsulated, but frequent metal mask changes are required reducing production efficiency
Solution Approach 1:
The pixel definition layer is segmented into a first pixel definition layer and a second pixel definition layer with inverted trapezoidal structures. This segmentation allows the encapsulation layer to be formed continuously without frequent metal mask changes, as the inverted trapezoidal structures provide built-in protection at cutting locations while maintaining a uniform pattern across the panel.
Solution Approach 2:
The second pixel definition layer with inverted trapezoidal structures is formed in advance before the encapsulation process. This preliminary action creates protective structures at potential cutting locations beforehand, eliminating the need for frequent metal mask changes during encapsulation and improving production efficiency.
2Reliability
If the OLED panel is cut after encapsulation, then individual panels are obtained, but water and oxygen easily invade from cutting locations reducing reliability
Solution Approach 1:
The inverted trapezoidal structures of the second pixel definition layer are formed in advance to prevent water and oxygen invasion at cutting locations. These structures create a protective barrier that counteracts the harmful effect of cutting-induced exposure, maintaining encapsulation reliability even after panel singulation.
Solution Approach 2:
The second pixel definition layer with inverted trapezoidal structures acts as a flexible protective film or shell at the cutting locations. This thin film structure provides continuous protection against water and oxygen penetration, maintaining the integrity of the encapsulation even after the panel is cut into individual displays.
3Reliability
If a second pixel definition layer with inverted trapezoidal structures is added, then water and oxygen resistance is improved, but the device structure becomes more complex
Solution Approach 1:
The second pixel definition layer with inverted trapezoidal structures serves multiple functions: it maintains the pixel pattern definition and simultaneously provides protective barriers at cutting locations. This multi-functionality improves encapsulation reliability without requiring entirely separate protective structures, thus limiting the increase in device complexity.
Solution Approach 2:
The protective function and pixel definition function are merged into a single second pixel definition layer. The inverted trapezoidal structures both define the pixel boundaries and create protection at cutting locations, combining multiple functions into one structure to minimize the increase in device complexity while maintaining improved reliability.
Data Source
AI summary
An organic light-emitting diode (OLED) panel is provided. The OLED panel includes: a substrate having a light emitting region and a non-light emitting region; and an organic flat layer, an anode, a first pixel definition layer, a light emitting layer, a cathode and an encapsulation layer stacked on the substrate. On the non-light emitting region, a second pixel definition layer is further disposed between the first pixel definition layer and the encapsulation layer, and is disposed adjacent to a cutting location of the OLED panellight emitting layer; and the second pixel definition layer is constructed as inverted trapezoidal structures spaced apart from each other.