Flexible Multi-Layer Package with Intermediate Binding Member
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Solution Overview
Problem
Existing flexible device packaging solutions, such as OLEDs, face challenges in achieving a low leakage rate for ambient substances like moisture and oxygen due to pinholes in inorganic/organic multi-layer structures, which are costly and difficult to produce without sufficient leakage performance.
Innovation Solution
A flexible multi-layer package with an inner and outer organic film barrier layer and an intermediate substance binding member between them, capable of binding ambient substances, reducing the number of molecules penetrating the inner barrier layer and maintaining the outer layer's leakage prevention capability over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple inorganic/organic layers are deposited to achieve low leakage rate, then leakage protection is improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent introduces an intermediate substance binding member positioned between the inner and outer barrier layers. This intermediary component binds substances that penetrate the outer barrier layer, preventing them from reaching the device. This mediator approach reduces the need for excessively complex multi-layer structures while maintaining low leakage rates.
Solution Approach 2:
The package employs a composite structure combining organic barrier layers with an inorganic substance binding member. This composite approach leverages the complementary properties of organic materials (flexibility, continuity) and inorganic materials (substance binding capability) to achieve effective protection without requiring numerous thin layers.
2Reliability
If many inorganic/organic layers are used to achieve sufficiently low leakage rate, then leakage protection is improved, but manufacturing cost increases
Solution Approach 1:
By introducing the intermediate substance binding member, the patent reduces the number of barrier layers needed to achieve the same leakage protection level. This intermediary component performs the substance binding function that would otherwise require multiple additional layers, thereby reducing manufacturing complexity and cost.
Solution Approach 2:
The patent extracts the substance binding function from the barrier layer structure itself and places it in a separate intermediate member. This separation allows for simpler, more cost-effective manufacturing of each component while achieving the combined effect of barrier protection and substance binding.
3Reliability
If inorganic coatings are deposited on flexible substrate, then leakage protection is improved, but pinholes allow substance penetration
Solution Approach 1:
The intermediate substance binding member acts as a mediator that compensates for the presence of pinholes in the inorganic barrier layer. By binding substances that penetrate through pinholes, this intermediary component maintains effective leakage protection even when perfect coating quality is not achieved.
Solution Approach 2:
The patent converts the harmful effect of pinholes into a beneficial scenario by positioning substance binding members to intercept and bind penetrating substances. Rather than requiring perfect coatings, the design accepts pinhole presence and uses the binding members to neutralize their harmful effect.
4Adaptability or versatility
If flexible package structure is used, then adaptability to flexible devices is improved, but achieving low leakage rate becomes more difficult
Solution Approach 1:
The patent uses a composite structure combining flexible organic barrier layers with an inorganic substance binding member. This composite approach maintains the flexibility needed for flexible devices while the inorganic binding member provides robust substance binding capability to achieve low leakage rates.
Solution Approach 2:
The package structure applies different material properties to different regions: organic materials provide flexibility and continuity, while localized inorganic substance binding members provide targeted substance binding at critical interfaces. This local quality differentiation achieves both flexibility and low leakage rate.
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 package achieves a low leakage rate of less than 10^-6 g/m²/day, making it cost-efficient and suitable for flexible devices like OLEDs, while maintaining flexibility and optical transparency, without the need for pinhole-free layers.
Implementation Method 1
an intermediate substance binding member which is provided between said inner and outer barrier layer of the multi-layer barrier to bind a fraction of the substance having penetrated the outer barrier layer
Implementation Method 2
one or several layers of inorganic coatings are deposited on the bottom side of the flexible substrate on which the device to be protected is mounted, and on top of the device
Data Source
Figure 1a~1b
Figure 2a~2b
AI summary
A package (1; 20) for protecting a device (2; 21) from ambient substances, the package comprising an enclosure surrounding the device (2; 21). The enclosure includes a multi-layer barrier (7; 24) and an internal substance binding member (14; 27) which is provided inside the enclosure to bind at least one of said ambient substances having penetrated the enclosure. The package (1; 20) further comprises an intermediate substance binding member (14; 29) which is provided between an inner (11a-b; 25) and an outer (16a-b; 28) barrier layer of the multi-layer barrier (7; 24) to bind a fraction of the substance having penetrated the outer barrier layer (16a-b; 28).