Hybrid Moisture-Barrier Layer for Flexible OLED Encapsulation
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Solution Overview
Problem
Organic electronic devices, such as OLEDs and organic solar cells, are vulnerable to moisture and oxygen penetration, which reduces their lifespan and functionality, especially when using flexible plastic substrates without adequate encapsulation.
Innovation Solution
A hybrid moisture-proof layer is formed by combining solution-cured layers with deposition layers, incorporating metal nanoparticles, and a mixed layer with differing metal types, to enhance moisture and foreign matter blocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a thin moisture-proof layer is applied on plastic substrate, then flexibility is maintained, but moisture and oxygen penetration increases
Solution Approach 1:
The patent uses a composite moisture-proof layer comprising multiple layers with different materials and formation methods. This includes a first moisture-proof layer formed by solution application and curing, and a second moisture-proof layer formed by deposition process, creating a composite structure that provides superior moisture and oxygen barrier properties while maintaining flexibility
Solution Approach 2:
The moisture-proof function is divided into multiple segments - a first moisture-proof layer and a second moisture-proof layer - each formed by different processes. The first layer provides base protection while the second layer enhances the barrier effect, collectively addressing the moisture penetration issue
2Object-affected harmful factors
If multiple moisture-proof layers are formed continuously, then moisture-proof performance improves, but manufacturing complexity increases
Solution Approach 1:
The patent merges two different moisture-proof layer formation methods into a single continuous manufacturing process. The first moisture-proof layer is formed by solution application and curing, followed directly by deposition of the second moisture-proof layer without breaking the manufacturing flow, thus improving performance while controlling process complexity
3Reliability
If metal nanoparticles are added to solution, then moisture-proof reliability improves, but solution formulation complexity increases
Solution Approach 1:
The patent incorporates metal nanoparticles into the solution-based moisture-proof layer formulation. The nanoparticles are dispersed in the solution at specific concentrations and the solution is then cured to form the first moisture-proof layer containing metal nanoparticles, enhancing reliability while managing formulation complexity through controlled parameter changes
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 hybrid layer effectively prevents moisture penetration, improves reliability, and reduces production time and costs while addressing defects like cracks and pinholes.
Implementation Method 1
a first moisture-proof layer formed by curing a first solution on the base film, a second moisture-proof layer formed by curing a second solution on the first moisture-proof layer
Implementation Method 2
a first moisture-proof layer formed by curing a first solution on the base film, a second moisture-proof layer formed by curing a second solution on the first moisture-proof layer
Implementation Method 3
including metal nanoparticles by adding metal nanoparticles to a thermocurable solution or a photocurable solution
Implementation Method 4
a third moisture-proof layer formed using a deposition process on the second moisture-proof layer
Implementation Method 5
a third moisture-proof layer formed using a deposition process on the second moisture-proof layer
Data Source
AI summary
Disclosed are a hybrid moisture-proof layer including a base film, a first moisture-proof layer formed by curing a first solution on the base film, a second moisture-proof layer formed by curing a second solution on the first moisture-proof layer, a mixed layer formed between the first moisture-proof layer and the second moisture-proof layer, and a third moisture-proof layer formed using a deposition process on the second moisture-proof layer, and a method of manufacturing the same.