Picture-Frame Insulating Layer for Sealing Etching Control

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Solution Overview

Problem

In the manufacturing of organic electroluminescence (EL) display devices, variations in the manufacturing environment lead to inconsistent removal of the sealing layer, resulting in the unintended removal of underlying layers and potential failure of terminal exposure in the picture-frame area.

Innovation Solution

The display device includes a pixel electrode, an organic light emitting layer, a counter electrode, a sealing layer, a drive circuit in the picture-frame area, and test electrodes, with a picture-frame insulating layer covering the first test electrode, allowing for precise confirmation of sealing layer removal and ensuring proper terminal exposure through electrical continuity testing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the sealing layer is removed by dry etching to perform terminal exposure, then the sealing layer formed in the picture-frame area is removed, but variations in manufacturing environment cause inconsistent removal thickness, leading to unintended removal of underlying layers and potential failure of terminal exposure

Engineering Contradiction:

Improveterminal exposure precisionVSAvoidterminal exposure reliability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies preliminary action by forming a picture-frame insulating layer in advance before the sealing layer removal process. This insulating layer serves as a sacrificial layer that is selectively removed along with the sealing layer during dry etching. The preliminary formation of this insulating layer structure enables controlled removal and prevents damage to underlying important layers, thereby improving both manufacturing precision and reliability of terminal exposure.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements beforehand cushioning by introducing a picture-frame insulating layer that acts as a protective buffer during the sealing layer removal process. This insulating layer absorbs the variability in etching depth caused by manufacturing environment fluctuations, preventing the etching process from penetrating too deeply and damaging underlying layers. The cushioning effect ensures consistent terminal exposure results despite variations in etching conditions.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Ease of manufacture

If the sealing layer thickness varies due to manufacturing environment variations, then the etching process removes inconsistent thickness, but this leads to removal of layers below the sealing layer that were not intended to be etched

Engineering Contradiction:

Improvesealing layer formationVSAvoidetching depth control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent introduces a picture-frame insulating layer as an intermediary element between the sealing layer and the underlying layers. During the dry etching process, this insulating layer serves as a mediator that is removed together with the sealing layer, providing a controlled interface that prevents direct exposure and potential damage to the underlying important layers. This intermediary structure enables easier manufacturing while maintaining precise etching depth control.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If dry etching is used to remove the sealing layer in the picture-frame area, then terminal exposure can be performed, but there is the risk of failure due to inconsistent removal thickness

Engineering Contradiction:

Improveterminal exposure efficiencyVSAvoidterminal exposure success rate

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-forming the picture-frame insulating layer structure before the sealing layer removal. This preliminary structure enables the dry etching process to proceed efficiently with consistent results, as the insulating layer provides a uniform removal target that compensates for sealing layer thickness variations. This approach maintains high productivity while improving the reliability and success rate of terminal exposure.

Inventive Principle:

Principle #10Preliminary action

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 ensures reliable and consistent terminal exposure by confirming the removal of the sealing layer and underlying insulating layers, maintaining the integrity of the display device and simplifying the manufacturing process.

Implementation Method 1

the sealing layer formed in the picture-frame area may be removed by dry etching or the like to perform terminal exposure

Methodology Applied

Scientific EffectDry etching:

Data Source

PatentUS10374199B2Display device and manufacturing method thereof

Publication Date: 2019.08.06 MAGNOLIA WHITE CORP

AI summary

A display device includes: a pixel electrode formed in a display area; an organic layer formed on the pixel electrode and including a light emitting layer; a counter electrode formed on the organic layer; a sealing layer formed on the counter electrode; a drive circuit formed in a picture-frame area as an area outside the display area and controlling light emission of the light emitting layer; a first test electrode formed in the picture-frame area and electrically separated from the drive circuit; and a picture-frame insulating layer formed on the first test electrode.