Flexible OLED Display Using Ultra-Thin Glass Substrate
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Solution Overview
Problem
Flexible organic light emitting displays using plastic substrates face a trade-off between flexibility and barrier characteristics, as thicker barrier layers are needed to prevent oxygen and water permeation, which complicates design and manufacturing and contradicts the desired slim size, while glass substrates are brittle and lack flexibility.
Innovation Solution
A flexible organic light emitting display is fabricated using an ultra-thin film glass substrate with aluminum silicide, where the aluminum silicide concentration is higher away from the TFT element, and a combination of adhesive and protective layers to enhance flexibility and barrier properties, allowing for a maximum curvature radius of 3mm without breaking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a plastic based substrate is used to realize flexible substrate, then flexibility is improved, but water vapor transmission rate increases causing oxygen and water permeation into the organic light emitting element
Solution Approach 1:
The patent uses a composite structure consisting of a plastic substrate combined with multiple inorganic barrier layers (SiOx, SiNx, AlOx) and organic buffer layers. This composite material approach allows the substrate to maintain flexibility while the inorganic layers provide effective barrier properties against water and oxygen permeation, resolving the contradiction between flexibility and barrier characteristics.
Solution Approach 2:
The patent employs thin film encapsulation technique where multiple thin inorganic and organic layers are deposited on the plastic substrate. These thin films provide barrier functionality while maintaining the overall flexibility of the substrate, enabling the display to be bent without compromising either flexibility or barrier performance.
2Reliability
If a multi-buffer layer with inorganic layers of SiOx and SiNx is deposited alternately to prevent water permeation, then barrier characteristic is improved, but thickness increases reducing flexibility
Solution Approach 1:
The patent uses thin film encapsulation with multiple alternating inorganic and organic layers deposited in sequence. Each layer is kept thin to maintain overall flexibility while the multi-layer structure provides effective barrier properties. The thin films collectively prevent water permeation without significantly increasing total thickness, thus preserving flexibility.
Solution Approach 2:
The alternating structure of inorganic barrier layers (SiOx, SiNx) and organic buffer layers creates a composite multi-layer system. This composite approach provides synergistic effects where inorganic layers block water molecules while organic layers provide stress relief and adhesion, achieving high barrier performance with controlled thickness.
3Reliability
If the thickness of the multi-buffer layer is increased to reach barrier characteristic level, then water vapor transmission rate is reduced, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent employs a composite multi-layer structure with alternating inorganic and organic layers. This composite design achieves low water vapor transmission rate through the synergistic barrier properties of multiple materials rather than relying on a single thick layer, thereby reducing overall structural complexity while maintaining effective barrier performance.
Solution Approach 2:
The barrier function is segmented into multiple thin alternating layers of different materials (inorganic SiOx, SiNx and organic buffer layers) rather than using a single thick barrier layer. This segmentation allows each layer to contribute specific properties (barrier, adhesion, stress relief) and simplifies manufacturing by enabling deposition of thin layers using standard techniques.
Data Source
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Figure 5(a)~5(f)
AI summary
A flexible organic light emitting display and a method of fabricating the same are disclosed in which flexible organic light emitting display may be realized without a plastic based substrate, and at the same time an ideal WVTR characteristic level for stably driving an organic light emitting element without deterioration may be realized. The flexible organic light emitting display comprises a first ultra-thin film glass substrate (110) that includes aluminum silicide (111); a thin film transistor (TFT) element (120) arranged on the first ultra-thin film glass substrate (110); and an organic light emitting element (130) arranged on the TFT element (120).