Laser Sealing Apparatus for OLED Substrate Encapsulation
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Solution Overview
Problem
Existing sealing methods for organic light-emitting display devices are inadequate in completely blocking moisture and oxygen, leading to reduced lifespan and efficiency, and are complex to implement.
Innovation Solution
A sealing apparatus and method using a measuring unit to assess the pattern of a sealing unit, a laser beam irradiation device to apply a focused laser beam, and a control unit to adjust the beam's path and size, ensuring effective sealing with a frit as the sealant between substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing methods (inorganic thin film lamination or absorbent formation) are used, then the sealing process can be implemented, but the sealing quality is insufficient to completely block moisture and oxygen
Solution Approach 1:
The patent changes the physical and chemical parameters of the sealing material by using frit (glass powder) instead of conventional inorganic thin films or organic polymers. The frit is applied as a paste and then sintered at high temperature to form a glass-based seal that provides superior barrier properties against moisture and oxygen penetration, directly resolving the insufficient sealing quality issue.
Solution Approach 2:
The patent employs composite sealing structure by combining frit (glass powder) with metal electrodes and organic light-emitting layers. The frit forms a glass-ceramic composite seal that integrates structural support, electrical conductivity, and moisture barrier functions, achieving complete blocking of harmful factors that conventional single-material sealing cannot accomplish.
2Reliability
If frit is used as sealant to improve adhesion between OLED substrate and encapsulation substrate, then sealing effectiveness is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges multiple functions into the frit sealing layer: adhesion between substrates, moisture barrier, oxygen barrier, and structural support. By combining these functions into a single material system, the patent reduces the need for separate sealing components and simplifies the overall manufacturing process despite the advanced material requirements.
Solution Approach 2:
The patent replaces conventional mechanical sealing methods (physical lamination of thin films) with a chemical-thermal process using frit sintering. The frit paste is applied and then sintered at high temperature to form a strong, integrated seal, substituting mechanical assembly with a more reliable thermal-processing approach that simplifies process control.
3Manufacturing precision
If laser beam irradiation is used to cure frit and seal the substrate, then sealing quality is enhanced, but processing time increases due to laser beam movement
Solution Approach 1:
The patent applies the frit in a pre-formed paste pattern before laser irradiation, positioning the material exactly where sealing is needed. This preliminary positioning eliminates the need for broad-area irradiation and allows the laser to follow a precise, optimized path, reducing processing time while maintaining high sealing quality through targeted energy delivery.
Solution Approach 2:
The patent uses periodic laser beam irradiation to cure the frit material along the sealing path. The laser is applied in controlled pulses or segments along the predetermined path, allowing efficient heat accumulation and curing without continuous irradiation, thereby reducing total processing time while ensuring complete sealing quality.
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 sealing quality, reduces processing time, and effectively protects organic light-emitting devices from moisture and oxygen, improving encapsulation efficiency.
Implementation Method 1
Laser beams are irradiated onto the sealing units of the organic light-emitting display device while moving a laser beam irradiation device. The frit is cured, thereby sealing the substrate by using the laser beam irradiation device.
Data Source
AI summary
The sealing apparatus includes a measuring unit moving above a sealing unit to measure a pattern of the sealing unit, a laser beam irradiation device moving along the measuring unit to irradiate a laser beam onto the sealing unit, and a control unit controlling a moving path and a size of a focusing area of the laser beam irradiation device according to the pattern of the sealing unit that is measured in the measuring unit.