OLED Panel Thickness Reduction via Layer Merging
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Solution Overview
Problem
The increasing number of layers in OLED display panels leads to increased thickness, lengthening the optical path, and reducing luminous flux efficiency.
Innovation Solution
Incorporating a touch screen layer and/or polarizer layer made of inorganic materials within the thin film packaging layer, which also serves to prevent moisture and oxygen permeation, while reducing the number of inorganic material layers and using an organic bonding layer to fix these layers, thereby reducing the panel's thickness and enhancing luminous flux efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of layers in the thin film packaging layer is increased to improve moisture and oxygen barrier performance, then the protection against moisture and oxygen permeation is improved, but the thickness of the OLED display panel increases and the optical path length increases, reducing luminous flux efficiency
Solution Approach 1:
The patent combines the protective function of inorganic material layers with the functional layers (touch screen layer and polarizer layer) by positioning at least one of these functional layers within the thin film packaging layer structure. This merging allows the functional layers to contribute to both their primary functions and the moisture/oxygen barrier function, thereby reducing the need for additional dedicated inorganic material layers and reducing overall panel thickness while maintaining protection performance.
Solution Approach 2:
The patent makes the touch screen layer and/or polarizer layer serve multiple functions: their original functions (touch sensing and light polarization) plus the function of preventing moisture and oxygen permeation. By making these layers multi-functional, the patent eliminates the need for separate dedicated barrier layers, thereby reducing the total number of layers and panel thickness while maintaining effective moisture and oxygen protection.
2Reliability
If the number of layers in the thin film packaging layer is increased to improve moisture and oxygen barrier performance, then the protection against moisture and oxygen permeation is improved, but the optical path length increases, reducing luminous flux efficiency
Solution Approach 1:
The patent merges the barrier function with functional layers, reducing the number of separate inorganic material layers needed. This reduction shortens the optical path length that light must travel through, thereby reducing light absorption and scattering losses, and improving luminous flux efficiency while maintaining effective moisture and oxygen protection.
Solution Approach 2:
By making functional layers multi-functional (serving as both functional elements and barrier layers), the patent reduces the total layer count and optical path length. This minimizes energy loss from light absorption and scattering in the packaging structure, thereby improving luminous flux efficiency while maintaining reliable moisture and oxygen protection.
3Length of stationary object
If the number of inorganic material layers is reduced to decrease panel thickness, then the panel thickness is reduced and luminous flux efficiency is improved, but the moisture and oxygen barrier performance may be compromised
Solution Approach 1:
The patent makes the touch screen layer and/or polarizer layer serve as barrier layers against moisture and oxygen permeation in addition to their primary functions. This multi-functionality allows the patent to reduce the number of dedicated inorganic material layers and overall panel thickness while maintaining effective moisture and oxygen protection through the functional layers themselves.
Solution Approach 2:
The patent combines the barrier function with the functional layers by positioning them within the thin film packaging layer structure. This merging allows the functional layers to provide both their primary functions and moisture/oxygen protection, enabling reduction in the number of inorganic material layers and panel thickness while maintaining reliable barrier performance.
4Device complexity
If the number of layers is reduced to improve luminous flux efficiency, then the manufacturing complexity is reduced and production cost is lowered, but the structural integrity and protection function may be compromised
Solution Approach 1:
The patent merges multiple functions into fewer layers by positioning the touch screen layer and/or polarizer layer within the thin film packaging layer structure. This merging reduces the total number of layers and manufacturing steps while maintaining both structural integrity and protection function, as the functional layers themselves provide the barrier protection rather than requiring separate dedicated barrier layers.
Solution Approach 2:
The patent makes functional layers multi-functional, allowing them to provide both their primary functions and structural protection/moisture barrier functions. This reduces the number of separate layers needed, simplifying manufacturing and reducing complexity while maintaining structural integrity and protection function through the multi-functional design.
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 reduces the number of layers and thickness of the OLED display panel, minimizing the optical path length and improving luminous flux efficiency while maintaining the functional integrity of the touch screen and polarizer layers.
Implementation Method 1
The plurality of inorganic material layer is configured to prevent moisture and oxygen from permeating
Implementation Method 2
The plurality of organic material layer is configured to reduce pressures on the inorganic material layer, and to prevent the inorganic material layer from being cracked or even broken due to an external force
Implementation Method 3
the bonding layer is configured to fix the touch screen layer or the polarizer layer
Data Source
AI summary
An organic light-emitting diode display panel may include a base substrate, an array structure layer, an organic light-emitting layer, a thin film packaging layer, a touch screen layer, and a polarizer layer. The array structure layer, the organic light-emitting layer, and the thin film packaging layer may be sequentially arranged on the base substrate. At least one of the touch screen layer and the polarizer layer may be located in the thin film packaging layer. An inorganic material layer in the thin film packaging layer may be replaced by the touch screen layer and/or the polarizer layer arranged in the thin film packaging layer to reduce a thickness of an OLED display panel.