Segmented Sealing Sheet for Organic EL Displays
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Solution Overview
Problem
Existing methods for manufacturing organic electroluminescence (EL) display devices face challenges in reliably separating unnecessary portions of large-size sealing sheets, leading to potential leaks and reduced device lifetime due to unbalanced resin film and sealing agent heights, and difficulties in separating flexible sealing substrates without damaging the remaining sealing member.
Innovation Solution
A method involving a mother sealing sheet with a rectangular separation line, cut-outs at corner portions, and perforations on long and short sides to alleviate stress during separation, allowing for accurate positioning and reliable removal of unnecessary sealing sheet portions, thereby improving the manufacturing yield and reliability of organic EL display devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solid sealing method using a resin sheet is employed to protect the organic EL material from moisture, then the reliability of the organic EL display device is improved, but the manufacturing complexity increases due to difficulties in separating unnecessary portions of large-size sealing sheets
Solution Approach 1:
The sealing sheet is divided into multiple individual sealing sheets by forming separation lines, cut-outs at corner portions, and perforations on long and short sides. This segmentation allows easy separation of unnecessary portions while maintaining the integrity of the sealing sheet covering the display region, thus resolving the contradiction between reliability and manufacturing complexity.
Solution Approach 2:
The separation lines, cut-outs, and perforations are formed on the sealing sheet before it is adhered to the element substrate. This preliminary preparation of separation features enables straightforward removal of excess sealing material after bonding, simplifying the manufacturing process while ensuring reliable moisture protection.
2Productivity
If multiple organic EL display devices are manufactured simultaneously on a mother substrate, then the productivity is improved, but the manufacturing precision decreases due to unbalanced resin film and sealing agent heights during separation
Solution Approach 1:
By forming separation lines, cut-outs at corner portions, and perforations on the mother sealing sheet, the sealing sheet is segmented into multiple individual units. This segmentation enables precise separation of each device's sealing sheet without affecting others, maintaining height uniformity even when manufacturing multiple devices simultaneously, thus resolving the contradiction between productivity and manufacturing precision.
Solution Approach 2:
The separation features (cut-outs and perforations) are strategically positioned at specific locations (corner portions and sides) of the sealing sheet. This localized approach ensures that separation forces are applied at optimal points, preventing deformation and maintaining uniform sealing height across all devices manufactured on the mother substrate.
3Reliability
If the sealing sheet is tightly adhered to the element substrate, then the moisture sealing effectiveness is improved, but the ease of manufacture decreases due to difficulties in removing unnecessary sealing sheet portions
Solution Approach 1:
The sealing sheet incorporates separation lines, cut-outs at corner portions, and perforations that create predetermined separation paths. These segmented features allow the unnecessary portions of the sealing sheet to be easily removed after adhesion, while the portion covering the display region remains firmly attached, thus resolving the contradiction between sealing effectiveness and ease of manufacture.
Solution Approach 2:
The unnecessary portions of the sealing sheet are extracted from the complete sealing sheet through the separation features. The cut-outs at corner portions and perforations on sides create weak points that facilitate clean separation, allowing only the necessary sealing portion to remain adhered to the element substrate, thus enabling easy removal of excess material while maintaining effective sealing.
Data Source
AI summary
A solid sealing method of an organic EL display device is provided which effectively prevents influences of moisture and reduces manufacturing cost. A mother sealing sheet (400) and a mother element substrate (100) are adhered with a use of a positioning mark (+). A rectangular portion shown in a dotted line on the mother sealing sheet (400) is a separation line (41). An adhesive member is formed in the separation line (41), and the adhesive member is adhered to a display region (101) formed over the mother element substrate (100). A cut-out is formed at a corner portion and a short side portion of the rectangular separation line (41) and a cut-out and a bridge are formed on the long side portion. Thus, unnecessary portion of the mother sealing sheet can be removed without losing the reliability of adhesion.