OLED Display Spacer Height Variation for Bonding Stability
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Solution Overview
Problem
The mechanical strength of OLED displays is compromised due to empty spaces between the display and encapsulation substrates, which can lead to weak bonding and cracking when filler materials contact the sealant during the vacuum bonding process, resulting in instability and defects.
Innovation Solution
The implementation of spacers on the substrates to maintain a predetermined gap, with varying heights and configurations, controls the flow of filler materials and prevents premature contact with the sealant, ensuring stable bonding and enhanced durability against external impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the space between substrates is filled with filler material to improve mechanical strength, then durability against external impact is improved, but the filler can contact the sealant and cause cracks during hardening, reducing bonding stability
Solution Approach 1:
The sealant is applied and allowed to harden in advance before the filler material is introduced. This preliminary hardening creates a stable bonding structure that prevents the filler from causing cracks during the sealing process, thus maintaining both mechanical strength and bonding stability
Solution Approach 2:
The encapsulation space is divided into different regions: a first region near the edge where the sealant is located and a second central region where the filler is placed. This spatial segmentation prevents the filler from contacting the sealant, allowing both materials to perform their functions without interfering with each other
2Ease of manufacture
If uniform spacers are used to maintain gap between substrates, then manufacturing is simplified, but filler materials can still contact sealant at edge regions, causing bonding defects
Solution Approach 1:
Instead of using uniform spacers throughout, the invention employs spacers with varying heights: taller spacers at the edge regions near the sealant and shorter spacers in the central region. This local differentiation ensures that the gap between substrates is precisely controlled at critical locations where filler-sealant contact would occur, while maintaining reasonable manufacturing complexity
Data Source
AI summary
An organic light emitting diode display and a method for manufacturing the same are provided. The organic light emitting diode display includes a display substrate having an organic light emitting diode, an encapsulation substrate arranged opposite to the display substrate, and a sealant is applied between the display substrate and the encapsulation substrate to bond and form a hermetically sealed enclosed space therein. A filler may also be provided in some of the enclosed space. Spacers are formed on at least one of the display substrate and the encapsulation substrate to maintain a predetermined gap between the display substrate and the encapsulation substrate. The heights of the spacers are gradually increased from a central portion of the display substrate toward edges of the display substrate.