Color-Developing Encapsulation for Flexible OLED Crack Detection

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Solution Overview

Problem

Flexible OLED substrates face issues with cracks in the thin-film encapsulation layer during laser cutting, leading to moisture penetration and quality control challenges due to the slow and hidden nature of crack extension.

Innovation Solution

Incorporating a color development reaction mechanism using a first and second color rendering material within accommodating structures on the substrate, where a color change indicates a crack in the encapsulation layer, allowing for timely detection and prevention of moisture intrusion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If laser cutting is used to produce flexible OLED panels, then cutting speed and production efficiency are improved, but cracks occur in the thin-film encapsulation layer due to thermal expansion and contraction

Engineering Contradiction:

Improvecutting speedVSAvoidencapsulation layer integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-coating the encapsulation layer with a crack resistance layer before laser cutting. This layer is applied in advance to prevent crack formation during the subsequent cutting process, addressing the thermal stress issue before it occurs

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The crack resistance layer serves as a cushioning layer that absorbs and distributes the thermal stress generated during laser cutting. This beforehand cushioning prevents the stress from concentrating and causing cracks in the encapsulation layer

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Measurement precision

If quality inspection is performed on produced screens, then production quality can be monitored, but extended cracks are difficult to detect due to the slow penetration process of moisture

Engineering Contradiction:

Improvecrack detection accuracyVSAvoidtime for moisture penetration

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent converts the harmful effect of moisture penetration into a beneficial detection mechanism. By introducing a color rendering material that reacts with moisture, the slow and hidden moisture penetration process becomes a visible color change that can be easily detected during quality inspection

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent uses color changes as a detection mechanism. The color rendering material changes color when it comes into contact with moisture that has penetrated through cracks, making invisible defects visible and enabling accurate quality inspection

Inventive Principle:

Principle #32Color changes

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

Enables effective detection of cracks in the encapsulation layer post-cutting, ensuring the quality of flexible electroluminescent devices by visually identifying color changes, thereby preventing moisture intrusion and maintaining device integrity.

Implementation Method 1

the first color rendering material and the second color rendering material are capable of producing a color development reaction after mixture

Methodology Applied

Scientific EffectColor development reaction:

Data Source

PatentUS11482693B2Electroluminescent device including color rendering materials

Publication Date: 2022.10.25 BEIJING BOE TECH DEV CO LTD

AI summary

An electroluminescent device, includes: a base substrate; a light emitting unit provided on the base substrate; a first accommodating structure surrounding the light emitting unit and provided on the base substrate; a first color rendering material filled in the first accommodating structure; a first inorganic thin film encapsulation layer covering the light emitting unit and the first color rendering material; a second accommodating structure provided on one side of the first inorganic thin film encapsulation layer distal to the first color rendering material; a second color rendering material filled in the second accommodating structure; and a second inorganic thin film encapsulation layer sealing the second color rendering material in the second accommodating structure; wherein the first color rendering material and the second color rendering material are capable of producing a color development reaction after mixture.