OLED Sealing Substrate with Carbon Fiber Conductive Layers
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Solution Overview
Problem
Large OLED displays face issues with moisture and oxygen penetration, leading to performance degradation, and increased wiring resistance causes signal transmission delays (RC delay), affecting luminance uniformity.
Innovation Solution
A display device with a sealing substrate composed of a resin matrix and carbon fibers, incorporating multiple metal layers and conductive bonding layers to enhance sealing and reduce signal line resistance, eliminating the need for a flexible printed circuit board to simplify the structure and manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the display device uses a conventional sealing substrate without carbon fibers, then the manufacturing process is simpler, but the sealing function against moisture and oxygen penetration is insufficient
Solution Approach 1:
The sealing substrate is constructed as a composite structure comprising a base substrate and a carbon fiber layer. The carbon fiber layer provides enhanced barrier properties against moisture and oxygen penetration, while the base substrate maintains structural integrity. This composite approach resolves the contradiction by improving sealing reliability without excessively complicating the manufacturing process, as the carbon fiber layer can be applied as a coating or laminate.
Solution Approach 2:
The invention modifies the sealing substrate by introducing carbon fibers with specific properties (high aspect ratio, conductive characteristics) to change the physical and chemical parameters of the substrate. This parameter change enhances the sealing function and electrical conductivity simultaneously, addressing the reliability issue without requiring complete redesign of the manufacturing process.
2Device complexity
If the display device uses long signal lines to connect the driving driver outside the display unit, then the device structure is simplified, but wiring resistance increases causing RC delay and luminance uniformity deterioration
Solution Approach 1:
The invention changes the electrical parameter of the signal transmission path by incorporating a carbon fiber layer in the sealing substrate. This carbon fiber layer provides additional conductive pathways, effectively reducing the overall wiring resistance and RC delay. The parameter change in electrical conductivity resolves the contradiction between simplified device structure and maintained signal transmission quality.
Solution Approach 2:
The carbon fiber layer acts as an intermediary conductive element between the driving driver and the display unit. It provides alternative current paths that bypass the high-resistance portions of the signal lines, thereby reducing RC delay without requiring redesign of the overall device structure or signal line routing.
3Device complexity
If the display device eliminates the flexible printed circuit board to simplify structure, then manufacturing is easier and cost is reduced, but alternative connection methods must be implemented between substrate and sealing substrate
Solution Approach 1:
The invention merges the sealing function and the electrical connection function into a single integrated structure. The sealing substrate with carbon fiber layer simultaneously provides environmental sealing and electrical conductivity for signal transmission. This merging eliminates the need for separate flexible printed circuit boards while maintaining ease of manufacture, as the carbon fiber-integrated sealing substrate can be bonded directly to the display substrate in a single process step.
Solution Approach 2:
The sealing substrate is designed to perform multiple functions: providing environmental sealing against moisture and oxygen, and serving as an electrical connection path through the carbon fiber layer. This multi-functionality eliminates the need for separate connection components like flexible printed circuit boards, simplifying the overall device structure while maintaining ease of manufacture through direct bonding processes.
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
The solution effectively prevents moisture and oxygen ingress, improves sealing, minimizes RC delay, and maintains luminance uniformity in large OLED displays, extending the device's lifespan and simplifying production.
Implementation Method 1
a plurality of second metal layers disposed at one surface of the composite member facing the plurality of pads and electrically connected to the plurality of pads, respectively, through a electrically conductive bonding layer
Implementation Method 2
the sealing substrate comprises a composite member comprising a resin matrix and a plurality of carbon fibers
Data Source
AI summary
A display device includes: a substrate; a display unit that is formed over the substrate; a driving driver positioned outside the display unit and including a plurality of signal lines; a sealing substrate fixed to the substrate by a bonding layer surrounding the display unit and the driving driver. The sealing layer includes a composite member including a resin matrix and a plurality of carbon fibers and a first metal layer positioned over the composite member. The display device further includes a plurality of pads positioned outside the bonding layer and electrically connected to the plurality of signal lines; and a plurality of second metal layers positioned over one surface of the composite member facing the plurality of pads and connected to the plurality of pads, respectively, through a conductive bonding layer.