Graded Diffusion Barrier Coatings for Flexible OLED Protection

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Solution Overview

Problem

Conventional organic light-emitting devices (OLEDs) are prone to degradation due to environmental factors like oxygen and water vapor, leading to instability and short lifespan, especially when using flexible plastic substrates that are not impervious to these reactive species, and existing diffusion barriers face issues with delamination due to material incompatibility.

Innovation Solution

A graded-composition diffusion-barrier coating is applied to the substrate, where the coating material's composition varies continuously across its thickness, reducing the diffusion rates of chemical species and preventing delamination by creating a smooth transition between the substrate and the coating, thereby enhancing the stability of OLEDs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If flexible plastic substrates are used to build OLEDs, then flexibility and ease of manufacture are improved, but resistance to oxygen and water vapor degradation worsens

Engineering Contradiction:
ImproveflexibilityVSAvoidresistance to oxygen and water vapor
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies composite materials by creating a multilayer barrier coating system comprising alternating polymeric layers and inorganic ceramic layers. This composite structure combines the flexibility and conformability of polymers with the low permeability and barrier properties of ceramics, achieving both flexibility and resistance to oxygen and water vapor degradation simultaneously

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent implements the nested doll principle by placing multiple barrier layers within each other in a hierarchical structure. The inorganic ceramic layers are embedded within the polymeric matrix, creating a nested configuration where each layer provides complementary barrier functions, with the ceramic layers blocking diffusion paths and the polymeric layers providing structural continuity and flexibility

Inventive Principle:
Principle #7Nested doll (Nesting)

2Reliability

If alternating layers of polymeric and ceramic materials are applied to improve barrier properties, then resistance to oxygen and water vapor is improved, but delamination occurs due to weak interfaces

Engineering Contradiction:
Improveresistance to oxygen and water vaporVSAvoidinterface strength
Core Design Contradiction:
ReliabilityVSStrength

Solution Approach 1:

The patent applies parameter changes by systematically varying the thickness, composition, and structural parameters of the alternating polymeric and ceramic layers. By optimizing these parameters, the coating achieves enhanced interlayer adhesion while maintaining low permeability, preventing delamination through careful control of layer parameters rather than relying solely on chemical compatibility

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent implements local quality by creating regions with different material properties and functions within the barrier coating. The polymeric layers provide flexibility and structural continuity in certain regions, while the inorganic ceramic layers provide enhanced barrier properties in other regions, with each layer optimized for its specific local function to prevent delamination

Inventive Principle:
Principle #3Local quality

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 graded-composition coating significantly reduces oxygen and water vapor transmission rates by over three orders of magnitude, extending the lifespan of OLEDs and maintaining light transmission with minimal reduction, making them more suitable for flexible and durable applications.

Implementation Method 1

a graded-composition diffusion-barrier coating is formed on at least a surface of the substrate... reducing the diffusion rates of chemical species

Methodology Applied
Scientific EffectDiffusion: Diffusion

Data Source

PatentUS8383214B2Diffusion barrier coatings having graded compositions and devices incorporating the same
Publication Date: 2013.02.26 BOE TECHNOLOGY GROUP CO LTD
  • US8383214B2 patent drawing
  • US8383214B2 patent drawing
  • US8383214B2 patent drawing

AI summary

A composite article comprises a substrate having at least a substrate surface and a graded-composition coating disposed on a substrate surface. The composition of the coating material varies substantially continuously across its thickness. The coating reduces the transmission rates of oxygen, water vapor, and other chemical species through the substrate such that the composite article can be used effectively as a diffusion barrier to protect chemically sensitive devices or materials. An organic light-emitting device incorporates such a composite article to provide an extended life thereto.