Inkjet Encapsulation for Thin OLEDs
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Solution Overview
Problem
Conventional methods for manufacturing organic light emitting devices struggle to produce thin devices due to the use of sealing substrates like glass or metal, which limits the thinness and display performance of the devices.
Innovation Solution
A method using an inkjet technique to form protection films on an organic light emitting device, where the substrate is loaded in different directions or positions to create non-overlapping stains, allowing for the use of both organic and inorganic films to seal the device, preventing degradation of display performance and enabling a thin profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealing substrate made of glass or metal is used in the conventional manufacturing method, then the organic light emitting device is well-sealed and protected, but the device thickness increases and a thin profile cannot be achieved
Solution Approach 1:
The patent replaces the conventional thick glass or metal sealing substrate with thin film encapsulation layers formed by inkjet printing. Multiple thin layers (organic and inorganic films) are deposited sequentially to create a protective barrier that is both thin and effective, enabling a thin-profile OLED while maintaining sealing performance.
Solution Approach 2:
The encapsulation structure is divided into multiple thin layers (first protection film, second protection film, and additional layers) rather than using a single thick sealing substrate. This segmented approach allows each layer to be optimized for specific functions while collectively achieving both thinness and reliable sealing.
2Ease of manufacture
If protection films are formed by inkjet method in a single direction, then the manufacturing process is simple, but stains overlap and display performance deteriorates
Solution Approach 1:
The patent introduces asymmetric printing directions for different encapsulation layers. The first protection film is printed in a first direction, while the second protection film is printed in a second direction that is different from the first. This asymmetric approach prevents stain overlap and maintains display quality without significantly complicating the manufacturing process.
Solution Approach 2:
The patent adds the dimension of printing direction orientation to the encapsulation process. By controlling the angular orientation of inkjet printing for different layers, the method prevents stain overlap that would occur with single-direction printing, thereby maintaining display performance while using a relatively simple inkjet-based approach.
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
This approach enhances display performance by dispersing stains and preventing their overlap, resulting in a thin-profile organic light emitting device with improved protection against external factors.
Implementation Method 1
forming a first protection film by loading the substrate on which the organic light emitting diode has been formed to an inkjet device in a first direction; and forming a second protection film by loading the substrate on which the first protection film has been formed in a second direction
Data Source
AI summary
A method for manufacturing an organic light emitting device is disclosed. In one embodiment, the method includes an organic light emitting diode comprising a first electrode, a light emission layer, and a second electrode on a substrate; forming a first protection film by loading the substrate on which the organic light emitting diode has been formed to an inkjet device in a first direction; and forming a second protection film by loading the substrate on which the first protection film has been formed in a second direction, the first and the second direction being formed differently from each other.