Optical Substrate Encapsulation for Water Vapor Infiltration
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Solution Overview
Problem
Display panels face challenges in reducing water vapor infiltration, which affects the reliability of optical substrates, especially those with wavelength conversion units that are susceptible to external moisture.
Innovation Solution
The optical substrate design includes a base layer, a bank layer with specific openings, a wavelength conversion unit, and a first encapsulating layer that covers the bank and base layer portions, reducing water vapor infiltration through a water-resistant effect achieved by materials like silicon nitride or silicon oxide, and optionally a second encapsulating layer for additional protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bank layer is separated from the edge of the base layer to facilitate manufacturing, then the ease of manufacture is improved, but water vapor infiltration increases due to exposed edges
Solution Approach 1:
The patent applies encapsulating layers (thin films) to cover the exposed edges and surfaces of the optical substrate. The first encapsulating layer covers the top surface and side surfaces of the bank layer and wavelength conversion unit, while the second encapsulating layer covers the edge of the base layer, creating a flexible barrier against water vapor infiltration without complicating the manufacturing process.
Solution Approach 2:
The patent implements a nested encapsulation structure where the first encapsulating layer is positioned within the overall substrate structure to protect internal components (bank layer and wavelength conversion unit), and the second encapsulating layer is nested to protect the outer edge of the base layer, creating multiple protective barriers at different levels.
2Reliability
If encapsulating layers are added to cover all surfaces and edges, then water vapor infiltration is reduced, but the device complexity increases
Solution Approach 1:
The patent divides the encapsulation function into two separate encapsulating layers with distinct roles: the first encapsulating layer protects the internal components (bank layer and wavelength conversion unit) by covering their top and side surfaces, while the second encapsulating layer protects the outer edge of the base layer. This segmentation allows each layer to be optimized for its specific protective function without unnecessary complexity.
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 configuration effectively reduces water vapor infiltration, enhancing the reliability of the optical substrate, particularly for wavelength conversion units and spliced displays, by ensuring the encapsulating layers contact and cover critical surfaces and edges, thereby preventing moisture-induced failures.
Implementation Method 1
a water-resistant effect achieved by materials like silicon nitride or silicon oxide
Data Source
AI summary
An optical substrate and a manufacturing method thereof are provided. The optical substrate includes a base layer, a bank layer, a wavelength conversion unit, and a first encapsulating layer. The bank layer is disposed on the base layer and includes a first bank portion separated from an edge of the base layer. The wavelength conversion unit is disposed on the base layer and is adjacent to a side of the first bank portion away from the edge. The first encapsulating layer is disposed on the bank layer, the wavelength conversion unit, and a portion of the base layer not covered by the bank layer and the wavelength conversion unit. In the optical substrate and the manufacturing method thereof provided by the embodiments of the disclosure, infiltration of water vapor may be reduced or reliability may be improved.