Flexible OLED Display Panel Warped Functional Layer Encapsulation
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Solution Overview
Problem
Flexible OLED display panels face encapsulation failure due to water and oxygen ingress through hollow areas, compromising the reliability of the display panel.
Innovation Solution
A display panel design featuring a substrate with a warped first functional layer and protruding portions forming cavities in the non-display area, where the light-emitting functional layer is split, effectively blocking water and oxygen ingress by creating a barrier between the opening area and the display area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a hollowed area is provided in the display area for disposing photosensitive elements, then the functionality and screen-to-body ratio are enriched, but water and oxygen can easily enter the display area through the hollowed area, resulting in encapsulation failure
Solution Approach 1:
The first functional layer is segmented to form multiple protruding portions that extend into the hollowed area, creating separate cavity structures. These protruding portions divide the potential water/oxygen ingress path into multiple segments, making it harder for moisture to reach the display area while maintaining the hollowed area for photosensitive elements.
Solution Approach 2:
The solution transitions from a two-dimensional planar functional layer to a three-dimensional structure with protruding portions extending vertically into the hollowed area. This dimensional change creates cavities that block water and oxygen paths while preserving the functional opening for photosensitive elements.
2Reliability
If the first functional layer is warped to form protruding portions with cavities, then water and oxygen ingress is blocked, but the structural complexity and manufacturing difficulty increase
Solution Approach 1:
The first functional layer is warped to form curved or arched protruding portions instead of sharp angular structures. This curvature facilitates the formation of effective cavity shapes that block water and oxygen while being more amenable to manufacturing processes like lamination or molding, reducing overall structural complexity.
3Reliability
If the included angle θ of the cavity side surface is optimized (0° < θ ≤ 60°), then water and oxygen blocking efficiency is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent specifies an optimized range for the included angle θ (0° < θ ≤ 60°) that balances water blocking efficiency with manufacturability. This parameter optimization ensures that the cavity geometry provides effective moisture barrier functionality while remaining feasible for standard manufacturing processes, avoiding excessively tight tolerance requirements.
Data Source
AI summary
A display panel has a first non-display area between an opening area and a display area. The display area surrounds the first non-display area. The opening area penetrates the display panel. The display panel includes a substrate, a first functional layer, and a light-emitting functional layer. The first functional layer has a protruding portion at a warped position and has a first opening penetrating the first functional layer at the warped position. The first opening extends into the protruding portion to form a cavity having bottom and side surfaces. An included angle θ formed between the bottom surface and at least a part of the side surface satisfies 0<θ≤90°. A light-emitting functional layer located at a side of first functional layer away from substrate includes a common layer in first non-displaying and display areas and is split at protruding portion.