Folded OLED Edge Seal Doubles Diffusion Path
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Solution Overview
Problem
Existing OLED devices face challenges in maintaining hermeticity, particularly at the perimeter edges, leading to moisture and oxygen ingress, which reduces illumination efficiency and the useful life of the device.
Innovation Solution
An enhanced edge seal design for OLED panels, involving a flexible, impermeable backsheet with a foldable structure that doubles the edge seal width, includes a sidewall and cover portion, and uses an adhesive to secure the seal, potentially incorporating a moisture-absorbing material to prevent delamination and improve mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional edge seal design is used, then the device structure is simple and easy to manufacture, but the diffusion path length for moisture and oxygen is short, leading to reduced shelf life and illumination efficiency
Solution Approach 1:
The seal structure is folded back onto itself, creating a nested configuration where the seal layer is embedded within itself. This nesting doubles the diffusion path length without requiring additional materials or significantly increasing structural complexity, thereby improving reliability while maintaining ease of manufacture.
Solution Approach 2:
The seal structure transitions from a single-layer planar configuration to a multi-layer folded configuration, effectively adding a dimensional aspect to the seal path. This dimensional change increases the diffusion path length from a single thickness to multiple folded layers, enhancing protection against moisture and oxygen ingress.
2Reliability
If the edge seal width is increased to prevent moisture and oxygen ingress, then the diffusion path length increases and shelf life improves, but the device area is reduced and manufacturing becomes more complex
Solution Approach 1:
The nested folded seal structure increases the effective seal width and diffusion path length without proportionally increasing the overall device footprint. By folding the seal layer back onto itself, the structure achieves enhanced protection while minimizing the space consumed by the seal, thereby preserving more active OLED area.
Solution Approach 2:
The seal is implemented as a flexible thin film that can be folded and conform to the device perimeter. This flexible film approach allows the seal to provide extended protection along the edges without requiring large amounts of material or occupying excessive device area, maintaining a compact form factor while enhancing reliability.
3Object-affected harmful factors
If a hermetic seal is implemented around the OLED perimeter, then protection against moisture and oxygen ingress is improved, but mechanical stability may be compromised and delamination may occur
Solution Approach 1:
The seal structure merges multiple functions into a single integrated component: it provides hermetic sealing, mechanical reinforcement, and delamination prevention simultaneously. The folded seal layer acts as both a barrier against moisture and oxygen and a structural element that reinforces the device edges, eliminating the need for separate components and maintaining mechanical stability.
Solution Approach 2:
The seal structure employs composite construction with multiple layers including the seal layer, adhesive layers, and potentially reinforcement materials. This composite approach combines materials with complementary properties to achieve both hermetic protection and mechanical stability, preventing delamination while blocking moisture and oxygen ingress.
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 enhanced edge seal effectively doubles the diffusion path length for moisture and oxygen, significantly increasing the OLED's shelf life and illumination efficiency while maintaining mechanical stability and preventing delamination.
Implementation Method 1
uses an adhesive to secure the seal
Implementation Method 2
potentially incorporating a moisture-absorbing material
Data Source
AI summary
A light source assembly and associated method of forming same includes a generally planar light emitting device having parallel first and second generally planar surfaces that are interconnected along a perimeter. A seal extends over at least a portion of the light emitting device. Further, a sidewall portion encloses the perimeter of a light emitting device, and a cover portion may extend over at least a portion of the light emitting device. The method includes folding perimeter edges of an enlarged backsheet, or providing a frame seal that is dimensioned so that perimeter edges may be folded over the light emitting device.