Nanocomposite Encapsulation for Organic EL Devices
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Solution Overview
Problem
Conventional encapsulation methods for organic electroluminescent (EL) devices are inadequate in preventing moisture and oxygen permeation, leading to device deterioration, complexity, and high costs, with existing solutions being brittle, non-transparent, and unsuitable for mass production.
Innovation Solution
A layered inorganic substance/polymer/curing agent nanocomposite encapsulation layer is applied to the organic EL unit, increasing the interlayer thickness and moisture and oxygen absorption capabilities, using materials like layered silicates and polymers, which are easily mixed and intercalated, forming a hermetically sealed device without the need for additional sealants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cap-shaped metal can or glass encapsulation is used, then moisture and oxygen permeation is prevented, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies a flexible polymer encapsulation layer instead of rigid metal cans or glass encapsulation. The polymer layer forms a thin-film barrier that prevents moisture and oxygen permeation while maintaining device flexibility and simplifying the encapsulation structure. This resolves the contradiction by providing effective protection without the complexity of traditional rigid encapsulation methods.
2Reliability
If a desiccant powder is placed in a recess, then moisture absorption is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts the desiccant function from a separate component (desiccant powder in recess) and integrates it into the polymer encapsulation layer itself. The polymer matrix incorporates moisture-absorbing agents directly, eliminating the need for separate desiccant containers and recess structures. This integration reduces device complexity while maintaining moisture absorption capability.
Solution Approach 2:
The patent combines multiple functions into a single polymer encapsulation layer: moisture barrier, oxygen barrier, and moisture absorption. By merging these functions into one integrated structure rather than using separate components, the device complexity is reduced while maintaining or improving protective performance.
3Reliability
If etched glass is used as encapsulation member, then moisture protection is provided, but impact resistance deteriorates due to brittleness
Solution Approach 1:
The patent replaces brittle etched glass with a flexible polymer encapsulation layer. The polymer material provides inherent flexibility and impact resistance while maintaining moisture protection capabilities. This resolves the contradiction by providing a material that is both protective against moisture and resistant to impact forces.
4Ease of manufacture
If film-type encapsulation is used, then manufacturing is simplified, but durability and reliability decrease due to poor moisture infiltration prevention
Solution Approach 1:
The patent uses a composite polymer encapsulation layer that combines multiple materials with complementary properties. The composite structure integrates moisture barrier agents, oxygen barrier agents, and desiccant components within the polymer matrix, achieving superior moisture and oxygen infiltration prevention while maintaining ease of manufacture through single-layer fabrication.
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 nanocomposite encapsulation layer significantly reduces moisture and oxygen permeation, enhancing the device's lifetime, durability, and reliability, allowing for mass production while eliminating the need for desiccants and sealants, and providing a lightweight, impact-resistant organic EL device.
Implementation Method 1
a layered inorganic substance/polymer/curing agent nanocomposite on the organic EL unit
Implementation Method 2
prevent moisture and oxygen permeation
Data Source
AI summary
An organic electroluminescent (EL) device including an organic EL unit sealed by an encapsulation layer comprising a layered inorganic substance/polymer/curing agent nanocomposite. The organic EL device according to the present invention may have a flat glass substrate.