Flexible OLED Display Porous LiF Gas Barrier

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Solution Overview

Problem

Flexible organic light-emitting display apparatuses face issues with gas permeation, particularly oxygen, which can damage the emission layer and lead to defective pixels, due to the use of traditional substrates and manufacturing processes that generate harmful gases during the formation of barrier layers.

Innovation Solution

Incorporating a porous LiF layer between the flexible substrate and the display portion, and optionally between the barrier layer and the display portion, to collect and prevent gas permeation, while also using an AlOx layer for additional moisture protection, thereby enhancing the encapsulation and reliability of the display.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional substrates and manufacturing processes are used, then the display apparatus can be manufactured with conventional methods, but gas permeation occurs and damages the emission layer

Engineering Contradiction:
Improvemanufacturing processVSAvoidemission layer integrity
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

A porous layer is introduced as an intermediary component between the flexible substrate and the emission layer. This porous layer acts as a mediator that selectively allows certain substances to pass while blocking harmful gases, thus protecting the emission layer without requiring complete changes to the manufacturing process.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent employs a porous layer with specific pore structures to prevent gas permeation. The porous material is designed with controlled porosity that blocks harmful gases while maintaining flexibility and compatibility with the manufacturing process, thus resolving the contradiction between ease of manufacture and emission layer protection.

Inventive Principle:
Principle #31Porous materials

2Reliability

If a porous layer is added to prevent gas permeation, then the emission layer is protected from damage, but the device structure becomes more complex

Engineering Contradiction:
Improveemission layer protectionVSAvoidlayer structure
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The porous layer is integrated into the existing device structure as a single functional component rather than multiple separate layers. This approach provides effective gas protection while minimizing the increase in structural complexity, as the porous layer can be formed in one step using conventional deposition techniques.

Inventive Principle:
Principle #31Porous materials

Solution Approach 2:

The porous layer serves multiple functions simultaneously: it prevents gas permeation, maintains flexibility of the device, and is compatible with existing manufacturing processes. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in device complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If multiple barrier layers are stacked to improve protection, then gas permeation is reduced, but the manufacturing process becomes more complex

Engineering Contradiction:
Improvegas permeationVSAvoidmanufacturing process
Core Design Contradiction:
Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Instead of stacking multiple dense barrier layers, the patent uses a single porous layer with optimized pore structure that achieves gas permeation prevention more efficiently. This approach reduces the number of manufacturing steps compared to multiple barrier layers while maintaining effective protection against harmful gases.

Inventive Principle:
Principle #31Porous materials

Solution Approach 2:

The porous layer is designed as a composite structure that combines different materials or phases to achieve both gas barrier properties and flexibility. This composite approach provides enhanced protection against gas permeation without requiring multiple separate barrier layers, thus simplifying the manufacturing process.

Inventive Principle:
Principle #40Composite materials

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 porous LiF layer effectively prevents gas from reaching the display portion, reducing the risk of damage and improving the product's lifetime and reliability by ensuring the emission layer remains functional, while the AlOx layer further safeguards against moisture ingress.

Implementation Method 1

a porous layer between the flexible substrate and the display portion... to collect and prevent gas permeation

Methodology Applied
Scientific EffectAbsorption: Absorption (physical)

Implementation Method 2

using an AlOx layer for additional moisture protection

Methodology Applied
Scientific EffectPhysical barrier protection: Physical Containment

Data Source

PatentUS9312512B2Flexible organic light-emitting display apparatus and method of manufacturing the same
Publication Date: 2016.04.12 SAMSUNG DISPLAY CO LTD
  • US9312512B2 patent drawing
  • US9312512B2 patent drawing
  • US9312512B2 patent drawing

AI summary

A flexible organic light-emitting display apparatus includes a flexible substrate, a barrier layer on the flexible substrate, a display portion on the barrier layer, an encapsulation layer covering the display portion, and a porous layer between the flexible substrate and the display portion.