OLED Display Panel Dam Layout for Tear-Resistant Cutting
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Solution Overview
Problem
The existing methods for manufacturing OLED display panels face issues with the micro-lens pattern dams being easily torn from adjacent layers during cutting, leading to reduced quality and reliability of the display panel.
Innovation Solution
The display panel design includes a first optical structure layer with pixel openings and grooves in the non-display area, where the dams intersect with the edge of the non-display area at specific included angles (80° to 100°), and a second optical structure layer with a higher refractive index than the first, filling the pixel openings and grooves, to prevent tearing during cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the micro-lens pattern dams are formed with strong adhesion to adjacent layers, then the cutting effect is improved, but the dams are easily torn from the layers during cutting
Solution Approach 1:
The dam structure is segmented into multiple portions (first dam portion, second dam portion, third dam portion) with different cross-sectional shapes. Each portion has optimized geometry to balance adhesion and cutting performance, preventing tearing while maintaining strong bonding.
Solution Approach 2:
Different portions of the dam structure have different local geometries and material properties. The first dam portion has a first cross-sectional shape optimized for adhesion, the second has a second shape for structural integrity, and the third has a third shape for cutting performance. This local variation resolves the contradiction between strong adhesion and resistance to tearing.
2Manufacturing precision
If multiple cutting operations are performed to remove excess blocking structures, then the cutting precision is improved, but the manufacturing time and complexity increase
Solution Approach 1:
The dam structure is pre-formed with optimized geometry during the inkjet printing process, including specific cross-sectional shapes that facilitate clean single-step cutting. This preliminary structuring eliminates the need for multiple cutting operations while maintaining high precision.
Solution Approach 2:
The cross-sectional parameters of the dam structure are optimized to enable clean cutting in fewer steps. By adjusting the geometry parameters (width, height, angle) of different dam portions, the structure is designed to achieve precise cutting results with reduced manufacturing steps.
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 ensures that the dams are tightly bonded to the layers without tearing, thereby improving the quality and reliability of the display panel by maintaining structural integrity during the cutting process.
Implementation Method 1
a refractive index of the second optical structure layer is greater than a refractive index of the first optical structure layer
Data Source
AI summary
A display panel includes a display area and a non-display area disposed on at least one side of the display area, and further includes an array substrate, a first optical structure layer, and a second optical structure. The first optical structure layer is provided with a plurality of pixel openings, grooves, and dams. The dams and the grooves intersect with an edge of the non-display area at an included angle, and the included angle is 80° to 100°.