Flexible Polymer Film Sealing for Large OLED Displays
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Solution Overview
Problem
OLED displays face deterioration due to moisture and oxygen infiltration, requiring effective sealing to enhance display quality and lifespan, especially as display sizes increase, necessitating a lightweight yet reliable sealing structure with improved productivity.
Innovation Solution
A manufacturing method for OLED displays involving a sealing structure composed of a flexible polymer film and metal layers, where the metal layers are connected to conductive pads through a conductive contact layer, allowing for roll-to-roll processing and lamination, which includes a getter layer to absorb moisture and oxygen, and additional layers for enhanced sealing and power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional sealing structure is used for large-size OLED displays, then sealing performance can be maintained, but the structure becomes heavy and productivity decreases
Solution Approach 1:
The patent employs flexible polymer films as the core sealing structure, replacing traditional rigid sealing materials. The polymer film is formed into a thin, flexible barrier that effectively seals the display unit while allowing for lightweight construction and integration with large-size displays. This flexible film approach maintains sealing performance while enabling simplified manufacturing processes for high productivity.
Solution Approach 2:
The sealing structure utilizes composite material layers including polymer films, metal layers, and organic encapsulation layers. These composite materials provide enhanced barrier properties against moisture and oxygen infiltration while maintaining flexibility and lightweight characteristics. The multi-layer composite structure optimizes both sealing performance and manufacturability for large-size OLED displays.
2Area of stationary object
If the display area is increased, then display quality is improved, but sealing becomes more difficult and structure becomes heavier
Solution Approach 1:
The flexible polymer film sealing structure can be easily scaled to large display areas without compromising sealing effectiveness. The film's flexibility allows it to conform to large substrate surfaces, and its thin-film nature prevents weight increase despite the larger coverage area required for big-size displays.
Solution Approach 2:
The patent transitions from traditional planar sealing approaches to a multi-dimensional encapsulation strategy using flexible films that can wrap around and seal the edges of large displays. This dimensional approach ensures comprehensive sealing coverage across large display areas while maintaining structural integrity.
3Reliability
If a thick sealing structure is used, then sealing performance is improved, but productivity and ease of manufacture decrease
Solution Approach 1:
The patent achieves effective sealing with thin polymer film structures rather than thick sealing layers. The flexible film provides sufficient barrier properties against moisture and oxygen infiltration while being thin enough to facilitate easy manufacturing, lamination, and integration processes. This thin-film approach significantly improves ease of manufacture compared to traditional thick sealing structures.
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 solution effectively seals OLED displays, improving their quality and lifespan by preventing moisture and oxygen infiltration, while simplifying the manufacturing process and reducing costs for large-size displays by using roll-to-roll processes.
Implementation Method 1
forming a getter layer, a bonding layer and a conductive contact layer around the display unit
Implementation Method 2
manufacturing a sealing member including a flexible polymer film and a metal layer formed on at least one side of the polymer film
Implementation Method 3
laminating the sealing member on the substrate using a roll lamination process such that the metal layer comes into contact with the conductive contact layer
Data Source
AI summary
A large size organic light emitting diode (OLED) display and manufacturing method thereof are disclosed. In one embodiment, the method includes i) forming a display unit including a plurality of pixels on a substrate, ii) forming a getter layer, a bonding layer and a conductive contact layer around the display unit and iii) manufacturing a sealing member including a flexible polymer film and a metal layer formed on at least one side of the polymer film. The method may further include laminating the sealing member on the substrate using a roll lamination process such that the metal layer contacts the conductive contact layer and curing the contact layer and the conductive contact layer.