Organic EL Display Sealer with Offset Buffer Layers
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Solution Overview
Problem
Organic electroluminescence (EL) display devices deteriorate quickly due to exposure to moisture and oxygen, making it difficult to maintain long-term performance due to imperfections in sealing techniques that fail to completely shield the display elements from the open air.
Innovation Solution
A sealer structure is implemented with multiple buffer and barrier layers, where each layer is larger than the previous one, and their patterns are shifted relative to each other to ensure comprehensive coverage of the display elements, preventing moisture and oxygen ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single sealing film is used to cover the organic EL elements, then the device structure is simple and manufacturing is easier, but the film cannot be completely free from defects such as pinholes and cracks, leading to poor sealing performance and quick deterioration
Solution Approach 1:
The sealer is divided into multiple buffer layers (first buffer layer, second buffer layer) and barrier layers stacked in sequence. Each layer serves as an independent sealing component, so that defects in one layer do not necessarily compromise the entire sealing system. This segmentation allows the sealing function to be distributed across multiple layers, improving overall reliability while managing complexity through modular design.
Solution Approach 2:
The sealing structure employs a nested configuration where the first buffer layer is covered by the first barrier layer, which is in turn covered by the second buffer layer, and finally the second barrier layer. Each layer is positioned to cover the layers below it, creating a nested protective structure that enhances sealing performance through multiple redundant barriers against moisture and oxygen.
2Reliability
If the buffer layers are aligned perfectly with each other, then the manufacturing process is simpler, but the coverage may have gaps or weaknesses at the edges, reducing sealing effectiveness
Solution Approach 1:
The second buffer layer is deliberately positioned asymmetrically relative to the first buffer layer, with its pattern shifted in a predetermined direction. This asymmetric offset ensures that the edges of the buffer layers do not align perfectly, creating overlapping coverage that eliminates potential gaps or weak points in the sealing. The misalignment actually enhances sealing effectiveness by ensuring continuous coverage throughout the effective portion.
Data Source
AI summary
An array substrate includes an almost rectangular effective portion which is formed on the major surface of the substrate and includes a plurality of pixels for displaying images. An organic EL display device includes a sealer which is placed to cover at least the effective portion on the major surface of the array substrate. The sealer has a structure in which at least two almost rectangular buffer layers which have substantially the same pattern and barrier layers each of which is a pattern larger than each buffer layer and covers each buffer layer to shield it from the open air are stacked on each other. The shortest distance from one side of an end of the effective portion to one side of an end of the first buffer layer is different from the shortest distance to one side of an end of the second buffer layer.