Halogen-Containing Amorphous Oxide Packaging for OLED Stress Reduction
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Solution Overview
Problem
Current OLED device packaging faces issues with internal stress, defects, and increased manufacturing costs due to the use of multiple inorganic layers, which can lead to device failure from water vapor and oxygen ingress.
Innovation Solution
A packaging structure incorporating a halogen-containing amorphous solid oxide thin film with a crosslinked-polyhedra-network structure, combined with an inorganic layer, to provide a dense and hydrophobic barrier that effectively blocks external water vapor and oxygen, reducing the need for multiple layers and simplifying the fabrication process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple thin-film inorganic layers are used for packaging, then the barrier performance against water vapor and oxygen is improved, but the internal stress increases and reliability decreases
Solution Approach 1:
The patent changes the material parameter from conventional inorganic materials to halogen-containing amorphous solid oxide, which fundamentally alters the stress characteristics while maintaining barrier performance. This material substitution reduces internal stress in the packaging structure.
Solution Approach 2:
The patent employs composite material structure by combining halogen-containing amorphous solid oxide with specific inorganic layers, creating a multi-layer composite packaging structure that achieves both low stress and high barrier performance through synergistic material properties.
2Stress or pressure
If multiple alternating organic and inorganic layers are used, then the stress in each layer is reduced, but the manufacturing cost increases and fabrication process becomes more complicated
Solution Approach 1:
The patent extracts and eliminates the organic layers from the traditional alternating organic-inorganic multi-layer structure, retaining only the inorganic/halogen-containing oxide layers. This simplification maintains stress reduction benefits while significantly reducing fabrication complexity.
Solution Approach 2:
The patent merges the functions of multiple layers into a simplified structure where halogen-containing amorphous solid oxide layers provide both barrier and stress-management functions that were previously distributed across multiple organic and inorganic layers.
3Reliability
If multiple thin-film inorganic layers are deposited, then the barrier performance is improved, but defects such as cracks and impurities are inevitably introduced
Solution Approach 1:
The patent changes the deposition parameters and material composition to halogen-containing amorphous solid oxide, which forms denser films with fewer defects during deposition. This material parameter change inherently reduces cracks and impurities while maintaining barrier performance.
4Ease of manufacture
If a single inorganic layer is used for packaging, then the fabrication process is simplified, but the barrier performance against water vapor and oxygen is insufficient
Solution Approach 1:
The patent uses composite material composition within the inorganic layers, incorporating halogen-containing amorphous solid oxide with specific inorganic materials to create a multi-component structure that achieves superior barrier performance in fewer layers.
Solution Approach 2:
The patent optimizes the thickness, composition, and structural parameters of the halogen-containing oxide layers to achieve maximum barrier performance with minimal layer count, simplifying fabrication while maintaining reliability.
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 proposed solution significantly enhances the reliability and longevity of OLED devices by creating a robust, defect-free barrier that prevents water vapor and oxygen ingress, thereby improving the durability and reducing manufacturing costs.
Implementation Method 1
the amorphous solid oxide thin film in the at least one passivation layer has a crosslinked-polyhedra-network structure
Implementation Method 2
the device may be isolated from external water vapor and oxygen
Data Source
AI summary
A packaging structure includes at least one inorganic layer and at least one passivation layer. The at least one passivation layer includes a halogen-containing amorphous solid oxide thin film. The amorphous solid oxide thin film in the at least one passivation layer has a crosslinked-polyhedra-network structure. A display device includes a substrate, a display layer, and a packaging structure. The packaging structure further includes at least one inorganic layer and at least one passivation layer. The at least one passivation layer includes a halogen-containing amorphous solid oxide thin film. The amorphous solid oxide thin film in the at least one passivation layer has a crosslinked-polyhedra-network structure. A method for fabricating a display device includes providing a substrate, forming a display layer over the substrate, and forming a packaging structure over the display layer with the packaging structure including at least one inorganic layer and at least one passivation layer.