Flexible Protection Layer Transfer for OLED Encapsulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional flexible OLED displays face difficulties in attaching a large-sized flexible protection layer to a thin film encapsulation layer due to movement and handling issues, especially for large-sized displays.
Innovation Solution
A manufacturing method involving the formation of a flexible protection layer on a second substrate with a sacrificial layer, allowing easy attachment to a thin film encapsulation layer by fixing the protection layer with the second substrate, and subsequent separation of the substrate from the protection layer using a lift-off or wet-etching process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible protection layer is attached directly to a thin film encapsulation layer, then the protection layer can protect the OLED display, but the flexible protection layer moves and is difficult to handle during attachment, especially for large-sized displays
Solution Approach 1:
A second substrate is introduced as an intermediary carrier to support the flexible protection layer during the attachment process. The flexible protection layer is first formed on the second substrate, which provides mechanical support and prevents movement. Then the first substrate and second substrate are attached together, and finally the second substrate is separated from the flexible protection layer, leaving the protection layer properly attached to the thin film encapsulation layer.
Solution Approach 2:
The flexible protection layer is preliminarily attached to the second substrate before being transferred to the thin film encapsulation layer. This preliminary attachment ensures the protection layer is fixed and stable during handling, making the subsequent attachment process to the OLED display much easier and more reliable.
2Area of moving object
If the OLED display is made large-sized, then the display area increases, but the flexible protection layer becomes more difficult to attach due to increased movement and handling issues
Solution Approach 1:
The second substrate serves as a large-area support platform that accommodates the entire flexible protection layer for large-sized OLED displays. This intermediary structure distributes the handling requirements across the rigid second substrate rather than requiring direct manipulation of the large, flexible protection layer, making attachment feasible even for large display sizes.
3Reliability
If a flexible protection layer is used to protect the thin film encapsulation layer, then the OLED display achieves flexibility and protection, but the protection layer requires additional attachment steps that complicate the manufacturing process
Solution Approach 1:
The second substrate acts as a temporary intermediary that simplifies the overall manufacturing process by providing a stable platform for protection layer formation and transfer. Although it adds one additional component, it reduces the complexity of handling and attachment operations, making the net manufacturing process more manageable and reliable.
Solution Approach 2:
The second substrate serves as a temporary carrier that is discarded after serving its purpose of supporting the flexible protection layer during attachment. It is separated and removed in a final step, leaving only the necessary protection layer attached to the OLED display structure.
Data Source
AI summary
A method of manufacturing an OLED display includes: forming an organic light emitting element on a first substrate; forming, on the organic light emitting element, a thin film encapsulation layer that seals the organic light emitting element with the first substrate; providing a second substrate; forming a flexible protection layer on the second substrate; attaching the first substrate and the second substrate to each other; and separating the second substrate from the flexible protection layer.