Hybrid Encapsulation Layer for Flexible Displays

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Solution Overview

Problem

Flexible display apparatuses face challenges with encapsulation layers that fracture or damage when bent or folded, limiting their durability and functionality.

Innovation Solution

A display apparatus with a hybrid encapsulation layer comprising inorganic and organic layers, where the inorganic layers and organic layers are sequentially and alternately stacked, and the thickness of each layer decreases towards the tip portion, providing enhanced flexibility and protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional encapsulation layer is used to protect the display device, then protection and durability are improved, but flexibility is worsened causing fracture or damage when bent or folded

Engineering Contradiction:
Improveprotection and durabilityVSAvoidflexibility
Core Design Contradiction:
ReliabilityVSAdaptability or versatility

Solution Approach 1:

The encapsulation layer is divided into multiple thin inorganic layers and organic layers stacked alternately. Each layer has a thickness of 100-3000 Å, creating a segmented structure that maintains protection while allowing flexibility. The multiple thin layers can bend without fracturing compared to a single thick layer.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The encapsulation layer uses a composite structure combining inorganic materials (such as silicon nitride, silicon oxide, or silicon oxynitride) and organic materials (such as polyimide or acrylic resin). This composite structure provides both the protection of inorganic materials and the flexibility of organic materials, resolving the contradiction between durability and flexibility.

Inventive Principle:
Principle #40Composite materials

2Adaptability or versatility

If the encapsulation layer is made thinner to improve flexibility, then adaptability is improved, but protection and durability are worsened

Engineering Contradiction:
ImproveflexibilityVSAvoidprotection and durability
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

Instead of using a single thin layer that would be weak, the encapsulation is segmented into multiple thin layers (100-3000 Å each) stacked alternately. The cumulative thickness provides adequate protection while each individual thin layer maintains flexibility and prevents fracture.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The alternating inorganic and organic layers create a composite structure where the inorganic layers provide barrier protection and the organic layers provide flexibility. This composite approach achieves both protection and flexibility simultaneously, overcoming the trade-off between thickness and flexibility.

Inventive Principle:
Principle #40Composite materials

3Ease of manufacture

If a single-layer encapsulation structure is used to simplify manufacturing, then ease of manufacture is improved, but reliability is worsened due to fracture under bending

Engineering Contradiction:
Improvemanufacturing simplicityVSAvoidresistance to fracture
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The single-layer structure is segmented into multiple thin alternating layers of inorganic and organic materials. This segmentation prevents fracture under bending while the sequential deposition process using standard ALD and CVD techniques maintains manufacturing feasibility.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The alternating inorganic and organic layers form a composite encapsulation structure that prevents fracture. The inorganic layers (deposited by ALD) provide structural integrity and barrier properties, while the organic layers (deposited by CVD) provide flexibility and stress relief, together achieving fracture resistance.

Inventive Principle:
Principle #40Composite materials

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 solution enhances the flexibility and durability of the encapsulation layer, preventing damage from bending or folding and maintaining the integrity of the display device.

Implementation Method 1

at least one organic layer that includes a plasma polymer

Methodology Applied
Scientific EffectPlasma polymer: Plasma

Implementation Method 2

forming of the inorganic layer may include using an atomic layer deposition (ALD) method

Methodology Applied
Scientific EffectAtomic layer deposition: Physical Vapour Deposition

Data Source

PatentUS11849601B2Display apparatus and method of manufacturing the same
Publication Date: 2023.12.19 SAMSUNG DISPLAY CO LTD
  • US11849601B2 patent drawing
  • US11849601B2 patent drawing
  • US11849601B2 patent drawing

AI summary

A display apparatus includes a substrate, a display portion that includes a plurality of pixels disposed on the substrate, and an encapsulation portion that covers the display portion and includes a hybrid encapsulation layer that includes a plurality of inorganic layers and at least one organic layer that includes a plasma polymer. An end of the hybrid encapsulation layer includes a tip portion that includes an inorganic material and a multi-layered portion which extends from the tip portion toward a central portion of the substrate and in which the plurality of inorganic layers and the at least one organic layer are sequentially and alternately stacked, and a thickness of each of the inorganic layers and the organic layer decreases toward the tip portion.