OLED Substrate Bonding via Sealing Member Segmentation
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Solution Overview
Problem
Existing OLED displays have a dead space where the sealing member is formed, which cannot be used for image display, and there is a need to reduce this dead space and improve the bonding force between substrates.
Innovation Solution
The OLED display design includes a first and second substrate with a sealing member that fills through holes in the insulation and metal layers, and additional features such as a gold layer and reinforcing material to enhance adhesion, while the manufacturing method involves forming specific through holes and using a sealing material to bond the substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a sealing member is used to bond the first substrate and second substrate, then the bonding strength is improved, but the dead space increases reducing the display area
Solution Approach 1:
The sealing member is divided into multiple sealing branches instead of a continuous seal. Each sealing branch is spaced apart from others, creating discrete bonding points rather than a continuous dead space. This segmentation maintains bonding strength at critical points while freeing up peripheral areas for display purposes.
Solution Approach 2:
The sealing structure provides enhanced bonding strength locally at the sealing branches where adhesion is critical, while the display area remains free from sealing structures. The different diameters of through holes also create local variations in sealing intensity, with larger first through holes providing primary bonding and smaller second through holes providing additional localized reinforcement.
2Area of stationary object
If the sealing member width is reduced to minimize dead space, then the display area is increased, but the bonding strength and adhesion between substrates deteriorates
Solution Approach 1:
The sealing member incorporates multiple materials with different properties: a base sealing material providing general bonding, a gold layer providing enhanced adhesion and oxidation resistance, and reinforcing material providing additional structural support. This composite structure achieves high bonding strength with minimal material quantity, allowing reduced dead space while maintaining adhesion.
Solution Approach 2:
The gold layer acts as an intermediary between the sealing member and the substrates, providing superior adhesion properties. The gold layer bonds to both the sealing member and the substrate surfaces, creating a strong intermediate bonding interface that enhances overall adhesion even when the sealing member width is minimized.
3Ease of manufacture
If through holes are formed in the insulation and metal layers for sealing member insertion, then the sealing process is simplified, but the risk of delamination and oxidation of the sealing member increases
Solution Approach 1:
The gold layer creates an inert protective environment around the sealing member, preventing oxygen and moisture from reaching the sealing material through the through holes. Gold's inherent oxidation resistance provides a protective barrier that shields the sealing member from environmental degradation while allowing the simplified through-hole sealing structure to be used.
Solution Approach 2:
The gold layer serves as a protective intermediary between the sealing member and the external environment. It prevents direct contact between oxygen/moisture and the sealing material, thereby preventing oxidation and delamination while allowing the through-hole structure to remain exposed for sealing purposes.
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 reduces the dead space and improves the adhesion between substrates, preventing delamination and oxidation of the sealing member, thereby enhancing the overall performance of the OLED display.
Implementation Method 1
a sealing member configured to adhere the first substrate to the second substrate
Implementation Method 2
preventing delamination and oxidation of the sealing member
Implementation Method 3
a first insulation layer, a metal layer and a second insulation layer deposited on the first substrate
Data Source
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.