OLED Substrate Spacer Adhesion via Overcoat Layer
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Solution Overview
Problem
Manufacturing top-emission OLED display devices faces challenges such as achieving accurate assembly of array and color filter substrates, reducing the risk of short-circuiting metal wirings, and enhancing adhesive forces between the overcoat layer and transparent metal electrodes to prevent components from falling off, which affects product yield and display quality.
Innovation Solution
A substrate structure is developed with a base substrate, an overcoat layer, a spacer directly contacting the overcoat layer, and an electrode on the surface of the overcoat layer, using materials like organic resin and polyimide for the overcoat and spacer, respectively, to increase adhesive forces and prevent component detachment, while the electrode provides electrical conduction and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the spacer is disposed on the transparent metal electrode, then the assembly structure is formed, but the adhesive force is insufficient causing the spacer to fall off
Solution Approach 1:
The patent introduces an adhesive layer as an intermediary between the transparent metal electrode and the spacer. This adhesive layer specifically enhances the bonding strength between these two components, preventing the spacer from falling off during assembly and use, thereby resolving the adhesion insufficiency problem while maintaining high product yield rate.
2Reliability
If the metal wiring is exposed, then electrical conduction is achieved, but the risk of short-circuiting increases
Solution Approach 1:
The patent applies a protective coating over the exposed metal wiring. This coating converts the potential harm of exposed conductors (short-circuiting risk) into a beneficial protective structure that maintains electrical conduction while preventing harmful contacts, thus resolving the contradiction between achieving conduction and preventing short-circuits.
3Strength
If multiple layers are added to enhance adhesion, then bonding strength improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies the adhesive layer selectively only at specific locations where the spacer contacts the transparent metal electrode, rather than coating the entire surface. This localized application approach enhances bonding strength precisely where needed while minimizing the increase in manufacturing complexity and material usage.
Data Source
AI summary
A substrate, a display device including the substrate and a method of manufacturing the substrate are disclosed. The substrate includes: a base substrate; an overcoat layer on the base substrate; and a spacer on a surface of the overcoat layer facing away from the base substrate. The spacer is in direct contact with the surface of the overcoat layer facing away from the base substrate.