Flexible OLED Encapsulation with Segmented Inorganic Layers
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Solution Overview
Problem
Conventional encapsulation structures for OLED lighting devices fail to effectively prevent moisture infiltration through pinholes in inorganic layers, leading to reduced operational life due to oxidation and reaction with organic materials.
Innovation Solution
A stack of layers comprising at least one first organic layer and two inorganic layers, where the inorganic layers contact each other to separate the organic layer into multiple independent geometric regions, with the second organic layer covering the stack, made of materials like acrylic, epoxy, silicone, silicon nitride, silicon oxide, and silicon oxynitride, to prevent moisture permeation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the organic layer is made into multiple independent geometric regions by contacting inorganic layers, then moisture infiltration path is extended and pinhole permeation is prevented, but the device structure becomes more complex
Solution Approach 1:
The patent merges the functions of multiple layers into a unified encapsulation structure where the first inorganic layer, second inorganic layer, and third inorganic layer work together as an integrated system. The interfaces where these layers contact each other create the segmentation effect, combining the barrier function with the structural division in a single integrated design rather than separate components.
2Ease of manufacture
If conventional CVD and ink jet methods are used to form alternating inorganic and organic layers, then the manufacturing process is established, but pinholes are formed in the inorganic layers during the manufacturing process
Solution Approach 1:
The patent applies beforehand cushioning by introducing the third inorganic layer and creating the segmented structure in advance, before moisture infiltration can occur. This pre-established segmented architecture with multiple contacting inorganic layers provides built-in protection against pinhole formation effects, cushioning the device against moisture damage from the outset rather than attempting to repair defects after they form.
Data Source
AI summary
The present invention provides an encapsulation structure for a flexible display having an OLED lighting device on a flexible substrate. The encapsulation structure is disposed on the OLED lighting device, and includes a stack of layers for preventing moist from permeating into the OLED lighting device. The stack of layers includes at least one first organic layer and a plurality of inorganic layers wrapping the at least one first organic layer. Two inorganic layers of the stack of layers have interfacing faces that contact each other and separate the at least one first organic layer into a plurality of independent geometric regions. Through the present invention, moist undergoes an extended path to infiltrate, and is prevented from permeating into and eroding the OLED lighting device through pinholes of the inorganic layers, thereby prolonging the operation life of the OLED lighting device.