Hybrid Encapsulation Layer for Display Apparatus Impurity Prevention
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Solution Overview
Problem
Existing display apparatuses face issues with impure particles entering material layers during transportation between manufacturing chambers, leading to damage and detachment of encapsulation layers, which compromises the integrity of the display components.
Innovation Solution
A display apparatus with a multi-layered encapsulation structure comprising a first inorganic encapsulation layer, a hybrid encapsulation layer, and a second inorganic encapsulation layer, where the hybrid layer includes materials like alucone, zircone, or titanicone, and the layers are sequentially stacked to prevent impurity penetration and enhance adhesion, with a capping layer and protection layer to further secure the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If material layers are manufactured in different chambers using different processes, then manufacturing flexibility is improved, but impure particles may be inserted during transportation between chambers causing damage to encapsulation layers
Solution Approach 1:
The patent implements a nested multi-layer encapsulation structure where an inorganic encapsulation layer, hybrid encapsulation layer, and organic encapsulation layer are sequentially stacked. Each layer is embedded within the previous layer, creating a protective nested structure that prevents impurity penetration while maintaining manufacturing flexibility across different chambers
Solution Approach 2:
The patent employs a composite encapsulation system combining three different material types: inorganic material (e.g., silicon oxide, silicon nitride), hybrid material (e.g., alucone, zircone), and organic material (e.g., BCB, PI). This composite structure leverages the complementary properties of each material to provide comprehensive protection against impurities while allowing separate chamber manufacturing
2Reliability
If encapsulation layers are manufactured with multiple material layers, then protection against external water and oxygen is improved, but detachment among components may occur during manufacturing and assembly
Solution Approach 1:
The patent systematically varies material parameters across different encapsulation layers, including material composition (inorganic, hybrid, organic), layer thickness (first and second thicknesses), and thermal expansion coefficients. These parameter changes create a gradient structure that maintains strong adhesion while providing comprehensive environmental protection
Solution Approach 2:
The patent assigns different material properties to different regions of the encapsulation structure. The inorganic layer provides rigid protection at the base, the hybrid layer provides intermediate adhesion and flexibility, and the organic layer provides final sealing. Each layer is optimized for its specific function and position in the stack
3Object-affected harmful factors
If a multi-layered encapsulation structure is implemented, then impurity penetration prevention is improved, but device complexity increases
Solution Approach 1:
The patent divides the encapsulation function into three distinct segmented layers: inorganic encapsulation layer, hybrid encapsulation layer, and organic encapsulation layer. Each layer is manufactured separately in different chambers and then stacked, allowing independent optimization of each segment while achieving comprehensive impurity protection
Data Source
AI summary
A display apparatus includes a display device and an encapsulation layer covering the display device. The encapsulation layer includes a first inorganic encapsulation layer, a second inorganic encapsulation layer, and a hybrid encapsulation layer positioned between the first inorganic encapsulation layer and the second inorganic encapsulation layer. The hybrid encapsulation layer includes at least one of alucone, zircone, zincone, titanicone, and nickelcone.