Organic EL Display Panel Division Process with Adhesion Prevention
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Solution Overview
Problem
The existing methods for producing organic EL display panels face challenges such as increased production steps, adhesion of uncured photocurable resin to the panels, and potential deterioration of luminous characteristics due to moisture exposure, leading to reduced yield and higher production costs.
Innovation Solution
A process involving the formation of an adhesion preventive layer on the support substrate to prevent adhesive adhesion during panel division, combined with a limiting layer that doubles as a protective layer for the organic EL element, allowing for easier division and elimination of uncured adhesive, and using an organic fluorine compound as a charge injection or transport layer to enhance reliability and luminous characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an exposure mask is used to selectively cure the photocurable resin covering the display region, then the resin can be cured in the desired area, but the production steps are increased due to alignment and masking operations
Solution Approach 1:
The patent extracts and removes the exposure mask step from the production process. Instead of using a mask to selectively cure resin, the design allows uncured resin to naturally remain in dividing parts where it is not needed, eliminating the complex alignment and masking operations while maintaining precise selective curing through the adhesive application pattern itself
Solution Approach 2:
The patent segments the adhesive application into two distinct regions: a first adhesive application region where adhesive is applied to seal the display region, and a second adhesive application region (dividing part) where adhesive is intentionally not applied or is removed. This segmentation allows the photocurable resin to be selectively cured in the display region without requiring an exposure mask, as the uncured resin naturally remains in the dividing parts
2Manufacturing precision
If uncured photocurable resin is left in dividing parts after selective curing, then the display region is properly sealed, but the uncured resin adheres to the organic EL display panel and requires additional washing steps
Solution Approach 1:
The patent converts the harmful effect of uncured resin adhesion into a beneficial feature by designing the dividing part as an intentional non-adhesive zone. The uncured resin that would normally be a contaminant is instead used as a natural release agent, allowing easy separation of adjacent display panels without requiring washing steps, thereby improving productivity and yield
Solution Approach 2:
The patent performs preliminary action by intentionally leaving the dividing part uncured during the curing process. By pre-planning the uncured state in dividing parts as a design feature rather than a defect, the system enables automatic separation of panels without subsequent washing operations, converting a potential problem into a solution that maintains both sealing precision and high productivity
3Manufacturing precision
If washing is performed to remove uncured photocurable resin, then adhesion residue is eliminated, but the organic solvent penetrates into the organic EL element and deteriorates luminous characteristics
Solution Approach 1:
The patent extracts and eliminates the washing step entirely from the production process. By designing the dividing part to naturally prevent adhesive adhesion through intentional non-application or removal of adhesive in this region, uncured resin does not adhere to the display panel surface, making washing unnecessary and preventing solvent penetration that would damage the organic EL element's luminous characteristics
Solution Approach 2:
The patent implements self-service by designing the dividing part structure to automatically prevent adhesive contamination without requiring external washing operations. The intentional absence of adhesive in dividing parts creates a self-cleaning effect where uncured resin naturally remains non-adhesive, eliminating the need for solvent-based cleaning that would compromise the organic EL element's reliability
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 process simplifies the production steps, prevents adhesive residue, and ensures high reliability and luminous characteristics of the organic EL display panels by minimizing moisture penetration and eliminating the need for additional washing steps, thereby reducing production costs and improving yield.
Implementation Method 1
forming an adhesion preventive layer that inhibits adhesion to the adhesive on the principal plane of the support substrate between the luminous regions adjacent to each other
Implementation Method 2
a limiting layer that doubles as a protective layer for the organic EL element
Implementation Method 3
using an organic fluorine compound as a charge injection or transport layer to enhance reliability and luminous characteristics
Implementation Method 4
sealing the organic element such that the organic EL element is not brought into contact with moisture
Data Source
AI summary
The invention relates to a process of producing a display panel, the process comprising a step of providing plural display regions on the principal plane of a support substrate, a step of applying an adhesive to the principal plane of the support substrate so as to cover the display region, to form a seal layer and laminating a seal plate through the seal layer to form a laminate and a step of dividing the laminate at the positions between the display adjacent to each other to produce plural light emitting panels each having the display region, the process further comprising a step of forming an adhesion preventive layer that inhibits adhesion to the adhesive on the principal plane of the support substrate between the display regions adjacent to each other prior to the application of the adhesive.