Flexible OLED Delamination Prevention via Laser Release Layer
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Solution Overview
Problem
Current methods for producing flexible organic electroluminescence (EL) display devices often result in delamination issues between electrodes during the separation of the laminate structure from the support substrate, leading to non-functional pixels and reduced image quality.
Innovation Solution
The implementation of a laminate structure with a reflective layer between the pixel electrode and the base material, a semitransparent counter electrode, an organic electroluminescence function layer, and a transparent electrode, along with a gap created at the interface between the transparent electrode and the organic film, helps prevent delamination by simulating a delamination inducing point, thereby stabilizing the OLED layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a laminate structure including TFT and OLED on a resin film base material is separated from a glass support substrate by laser beam irradiation, then flexible display is achieved, but delamination occurs on the laminate structure between OLED electrodes
Solution Approach 1:
The patent introduces a release layer between the OLED laminate structure and the glass support substrate before assembly. This release layer is designed to be selectively removable by laser beam irradiation, allowing the OLED structure to be transferred to the flexible resin film base material without causing delamination of the OLED electrodes during the separation process
Solution Approach 2:
The release layer acts as an intermediary substance that facilitates the separation process. It provides a controlled interface between the rigid glass substrate and the flexible resin film, enabling the OLED structure to be released intact and transferred to the flexible substrate without damaging the electrode interfaces
2Ease of manufacture
If delamination occurs between OLED electrodes during substrate separation, then manufacturing complexity is reduced, but image quality deteriorates due to non-functional pixels
Solution Approach 1:
The release layer is pre-positioned at the interface between the OLED structure and the glass substrate before assembly. During separation, laser beam irradiation selectively removes this pre-positioned layer, enabling clean separation without disturbing the OLED electrode interfaces and maintaining pixel functionality
Solution Approach 2:
The patent converts the potential harm of delamination into a beneficial controlled separation process. By introducing the release layer, the separation process that could cause damage is transformed into a precise, controlled operation that protects the OLED electrodes while enabling flexible substrate integration
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
This configuration effectively reduces the likelihood of delamination at critical interfaces, ensuring the integrity of the OLED layer and maintaining image quality by creating a controlled gap that prevents unintended separation during the substrate removal process.
Implementation Method 1
a reflective layer that is disposed between the base material and the pixel electrode and reflects light
Implementation Method 2
an organic electroluminescence function layer that is a lamination including an organic light-emitting layer
Implementation Method 3
separating the laminate structure including the resin film from the support substrate by irradiating the back side of the glass plate with a laser beam
Data Source
AI summary
At the time of removing a flexible organic electroluminescence display device from a support substrate, delamination is prevented from occurring at a laminate structure of an OLED. The organic electroluminescence display device includes a flexible base material, a plurality of organic electroluminescence elements, each comprising a pixel electrode, a reflective layer that is disposed between the base material and the pixel electrode and reflects light, a semitransparent counter electrode that is disposed on a light-emitting surface side with respect to the pixel electrode, and an organic electroluminescence function layer that is a lamination including an organic light-emitting layer and disposed between the pixel electrode and the counter electrode, a transparent electrode laminated on the counter electrode, an organic film laminated on the transparent electrode 80, and a gap 84 generated at a part of an interface between the transparent electrode 80 and the organic film 82.