Curable Inkjet Films for OLED Encapsulation
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Solution Overview
Problem
Organic light-emitting diode (OLED) devices are susceptible to degradation by water and oxygen, requiring effective encapsulation methods to maintain stability and reliability, and existing deposition techniques often involve vacuum processing and mask alignment challenges.
Innovation Solution
The use of curable ink compositions deposited via inkjet printing to form a polymeric film as part of a multilayered encapsulation stack, which includes inorganic barrier layers, providing protection and improving light extraction and thermal dissipation, while eliminating the need for vacuum processing and mask alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum processing operations are used for deposition, then film quality and uniformity are improved, but device complexity and processing time increase
Solution Approach 1:
The patent replaces vacuum-based physical vapor deposition with inkjet printing technology that operates at atmospheric pressure. The inkjet printing system uses precisely controlled droplet deposition to form organic thin films, eliminating the need for vacuum chambers and complex vacuum pumping systems while achieving comparable film uniformity and quality
Solution Approach 2:
The invention changes the operating pressure parameter from vacuum conditions to atmospheric pressure, enabling deposition without vacuum processing equipment. The inkjet printing process controls film formation through precise droplet placement and curing parameters rather than vacuum conditions
2Manufacturing precision
If mask alignment techniques are used for patterning, then patterning precision is improved, but device complexity and processing time increase
Solution Approach 1:
The patent replaces mechanical mask alignment systems with digital patterning control through inkjet printing. The inkjet system uses computer-controlled droplet placement to achieve precise patterns without physical masks, eliminating alignment complexity while maintaining or improving patterning precision
Solution Approach 2:
The invention uses digital pattern data to directly control inkjet droplet placement, creating a digital copy or representation of the desired pattern that is transferred to the substrate through programmed deposition, eliminating the need for physical mask copies and alignment procedures
3Area of stationary object
If blanket coating methods are used for deposition, then coverage is improved, but material waste increases
Solution Approach 1:
The patent applies material only where needed through inkjet printing, depositing organic thin films selectively in specific patterns and locations rather than blanket coating entire substrates. This localized deposition approach achieves complete coverage of required areas while minimizing material waste
Solution Approach 2:
The invention uses partial deposition action by applying material only to the extent necessary for the active region and required coverage areas, avoiding excessive material application and subsequent waste that occurs with blanket coating methods
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
The solution effectively prevents degradation of OLED devices by forming stable, flexible polymeric films that enhance the mechanical and sealing properties of OLEDs, reducing material waste and processing complexity, and ensuring long-term stability and functionality.
Implementation Method 1
inkjet deposition can be used for the deposition of an organic thin film composition on a substrate
Implementation Method 2
followed by a curing process to form an organic layer on a substrate
Data Source
AI summary
The present teachings relate to various embodiments of a curable ink composition, which once printed and cured form high glass transition temperature polymeric films on a substrate such as, but not limited by, an OLED device substrate. Various embodiments of the curable ink compositions comprise di(meth)acrylate monomers, as well as multifunctional crosslinking agents.