Organic EL Panel Sealing Resin Application Method
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Solution Overview
Problem
Conventional organic EL panel manufacturing methods result in insufficient or excessive sealing resin layers, leading to gaps and moisture exposure that can damage organic EL elements, due to uniform application of resin across substrates.
Innovation Solution
A method where the sealing resin is applied in varying amounts to specific spots on the substrates, with less resin applied near the edges and more resin applied further inward, allowing for precise formation of the resin layer between substrates, preventing protrusion and gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If uniform resin application is used across the substrate, then the manufacturing process is simple, but the resin layer thickness is inconsistent causing gaps and excessive resin at edges
Solution Approach 1:
The resin application process is divided into multiple regions (edge region and inner region) with different resin amounts applied to each. The edge region receives less resin to prevent protrusion, while the inner region receives more resin to ensure adequate coverage, creating a non-uniform but optimized resin distribution pattern.
Solution Approach 2:
The substrate surface is segmented into multiple application regions based on distance from the edge. By dividing the resin application into discrete zones with different resin quantities, the process achieves precise control over resin layer thickness in different areas, resolving the contradiction between uniformity and simplicity.
2Reliability
If more resin is applied to prevent gaps, then sealing reliability improves, but resin protrusion at edges occurs
Solution Approach 1:
Different resin amounts are applied to different regions: the edge region receives reduced resin quantity to prevent protrusion and maintain shape control, while the inner region receives sufficient resin to ensure gap-free coverage and sealing reliability. This localized differentiation resolves the contradiction between reliability and shape control.
3Shape
If less resin is applied near edges, then resin protrusion is prevented, but gaps may form in the resin layer
Solution Approach 1:
The substrate is divided into edge regions and inner regions with distinct resin application quantities. The inner region receives sufficient resin to ensure complete coverage and prevent gaps, while the edge region receives controlled amounts to maintain shape precision. This segmentation allows simultaneous achievement of coverage accuracy and shape control.
Data Source
AI summary
A method for manufacturing an organic EL panel includes: applying sealing resin for forming a sealing resin layer to a plurality of spots on an application target surface of one of an EL substrate and a CF substrate, the application target surface being a surface to which the sealing resin is to be applied, and stacking the EL substrate and the CF substrate one on top of the other after the sealing resin is applied, and when the sealing resin is applied, the amount of the sealing resin applied to a spot near an edge of the application target surface is less than the amount of the sealing resin applied to a spot further inward than the spot near the edge.