Pixel-Spacing Insulating Structure for Impact-Resistant Displays
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Solution Overview
Problem
Display devices face challenges in maintaining robustness against external impact and preventing impurities from permeating, which can lead to defects and reduced performance.
Innovation Solution
Incorporating a metal layer between pixel areas with an inorganic insulating layer having a groove and an organic insulating layer filling the groove, along with a barrier layer to prevent impurity ingress and enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal layer is disposed between pixel areas, then electrical connection and structural support are improved, but susceptibility to external impact and impurity permeation increases
Solution Approach 1:
The patent employs a composite insulating layer structure combining inorganic insulating material and organic insulating material. The inorganic layer provides barrier properties against impurity permeation, while the organic layer fills grooves to provide mechanical cushioning against external impact. This composite approach resolves the contradiction by integrating materials with complementary properties that simultaneously address electrical connection reliability and protection against harmful factors.
Solution Approach 2:
The patent incorporates an organic insulating layer that fills grooves formed in the inorganic insulating layer, positioned between pixel areas. This organic layer acts as a cushioning element that absorbs external impact before it can reach and damage the metal layer or underlying structures. The beforehand cushioning prevents damage from external impact while the inorganic layer prevents impurity permeation.
2Object-affected harmful factors
If insulating layers are made thicker to prevent impurity permeation, then protection against impurities is improved, but structural robustness against external impact deteriorates
Solution Approach 1:
The patent divides the insulating function between two material types: inorganic insulating material for impurity barrier properties and organic insulating material for mechanical cushioning. This composite structure allows each material to optimize its function without compromise - the inorganic layer can be sufficiently thick for impurity protection while the organic layer provides the necessary mechanical flexibility for impact resistance.
Solution Approach 2:
The patent applies different material properties to different functional requirements within the insulating structure. The inorganic insulating layer is positioned to provide chemical stability and impurity barrier properties, while the organic insulating layer is positioned to provide mechanical cushioning. This local quality differentiation allows each material to be optimized for its specific function, resolving the contradiction between thickness for impurity protection and strength for impact resistance.
3Strength
If grooves are formed in the inorganic insulating layer to expose metal layer, then organic insulating layer can fill and provide cushioning, but manufacturing complexity increases
Solution Approach 1:
The patent forms grooves in the inorganic insulating layer before depositing the organic insulating material. This preliminary action of groove formation creates predetermined pathways and spaces that guide the subsequent organic layer deposition, ensuring proper filling and positioning. By performing this action in advance, the manufacturing process becomes more controlled and less complex than attempting to achieve the same result through simultaneous or sequential deposition without groove guidance.
Data Source
AI summary
A display device may include a substrate including a first pixel area on which a first pixel is positioned and a second pixel area on which a second pixel is positioned, a metal layer disposed on the substrate between the first pixel area and the second pixel area, an inorganic insulating layer disposed on the metal layer and having a groove exposing at least a portion of the metal layer, and an organic insulating layer filling the groove of the inorganic insulating layer.