OLED Substrate Sealing with Segmented Branches

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Solution Overview

Problem

OLED displays face challenges in reducing dead space and improving substrate sealing, leading to limitations in image display areas and bonding force.

Innovation Solution

The OLED display design includes a first substrate with a display area and a peripheral area, a second substrate, and a sealing member that fills through holes in the substrates, with a metal layer and insulation layers formed to enhance bonding, and additional features like gold layers and sealing branches to reinforce adhesion, using specific etching processes and materials to optimize sealing and reduce dead space.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a sealing member is used to bond substrates, then bonding force is improved, but dead space increases reducing display area

Engineering Contradiction:

Improvebonding forceVSAvoiddisplay area

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

The sealing member is divided into multiple sealing branches that extend from the peripheral sealing member toward the display area. This segmentation allows the bonding function to be distributed across multiple points rather than requiring a continuous large-area sealing member, thereby reducing dead space while maintaining bonding force.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sealing structure transitions from a two-dimensional planar sealing member to a three-dimensional structure with sealing branches extending in multiple directions. This dimensional change allows the sealing member to achieve bonding force through vertical adhesion and radial branching rather than relying solely on horizontal coverage area.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Area of stationary object

If the sealing member area is reduced to minimize dead space, then display area is improved, but bonding force decreases

Engineering Contradiction:

Improvedisplay areaVSAvoidbonding force

Core Design Contradiction:

Area of stationary objectVSStrength

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sealing branches are strategically positioned and sized to provide localized bonding strength where needed. The varying dimensions and positions of different sealing branches optimize the distribution of bonding force across the substrate interface, ensuring adequate adhesion with minimal overall sealing member area.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If conventional sealing structures are used, then manufacturing is simple, but delamination and oxidation occur reducing reliability

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidresistance to delamination and oxidation

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The sealing member incorporates a composite structure with a first insulation layer, metal layer with through holes, and second insulation layer. This composite material structure provides both mechanical bonding strength and chemical resistance to delamination and oxidation, while the through holes allow sealing material infiltration to enhance adhesion.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The metal layer with through holes acts as an intermediary between the insulation layers and the sealing material. The through holes allow the sealing material to penetrate and bond with underlying structures, creating a multi-level bonding interface that prevents delamination and oxidation while maintaining manufacturing feasibility.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 approach improves the adhesion force between substrates, reduces dead space, and prevents delamination and oxidation of the sealing member, resulting in a more efficient and reliable OLED display.

Implementation Method 1

a sealing member enabling the first substrate to adhere to the second substrate

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

The metal layer can contact the sealing member

Methodology Applied

Scientific EffectMetal sealing: Soldering

Implementation Method 3

a first insulation layer, a metal layer formed on the first insulation layer and having at least one through hole in the peripheral area, and a second insulation layer formed on the metal layer and having a second through hole

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS9184224B2Organic light-emitting diode display and manufacturing method thereof

Publication Date: 2015.11.10 SAMSUNG DISPLAY CO LTD

AI summary

An organic light-emitting diode (OLED) display and a manufacturing method thereof are disclosed. One inventive aspect includes a first substrate, a second substrate, and a first insulation layer, a metal layer and a second insulation layer formed on the first insulation layer. The metal layer is formed on the first insulating layer and has a first through hole. The second insulation layer is formed on the metal layer and has a second through hole. The inventive aspect further includes a sealing member formed by filling the first and second through hole so as to seal the first substrate to the second substrate.