Pixel Defining Layer Thinning Regions for Uniform OLED Encapsulation

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Solution Overview

Problem

Existing OLED display technologies face challenges in effective encapsulation due to low fluidity of fillers during the encapsulating process, leading to either excessive or insufficient filling of the encapsulating layer, which can result in poor performance or device failure.

Innovation Solution

The implementation of a pixel defining layer with thickness thinning regions on the array substrate, which guides the flow of fillers to ensure uniform filling of the encapsulating layer, preventing excessive or insufficient filling and enhancing the encapsulation of OLED devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional encapsulation methods are used without thickness thinning regions, then the encapsulating layer may be applied uniformly, but the fillers exhibit low fluidity leading to excessive or insufficient filling

Engineering Contradiction:

Improvefilling uniformityVSAvoidencapsulation quality

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The pixel defining layer is designed with different thickness regions: thickness thinning regions with smaller height and regular regions with larger height. This local variation in thickness creates corresponding shallow and deep regions in the encapsulating layer, enabling better control over filler distribution and improving both filling uniformity and encapsulation quality.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The thickness thinning regions are pre-formed in the pixel defining layer before the encapsulation process. These pre-formed structures guide the flow of fillers during encapsulation, ensuring uniform distribution and preventing both excessive and insufficient filling issues.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the pixel defining layer has uniform thickness, then the structure is simple, but the filler flow cannot be guided resulting in poor encapsulation

Engineering Contradiction:

Improveencapsulation qualityVSAvoidpixel defining layer structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The pixel defining layer incorporates thickness thinning regions with specific geometric patterns (such as line-shaped, grid-shaped, or dot-shaped structures) that create local thickness variations. These variations serve as flow guides for fillers during encapsulation, improving encapsulation quality while maintaining a relatively simple overall structure.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12048202B2Array substrate including pixel defining layer with spacer parts

Publication Date: 2024.07.23 BOE TECHNOLOGY GROUP CO LTD

AI summary

An array substrate includes a base substrate and a pixel defining layer on the base substrate. The pixel defining layer includes a plurality of thickness thinning regions. The thickness thinning regions have a smaller height than other areas of the pixel define layer on the base substrate. The plurality of the thickness thinning regions is configured to guide flow of fillers to form an encapsulating layer on the pixel defining layer.