OLED Thin Film Encapsulation UV Curing Adhesive Patterning
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Solution Overview
Problem
Current laminating film patterning processes for OLED displays, such as photolithography, laser cutting, and press processes, can damage the displays, increase process time and cost, and make it difficult to easily change patterns due to model changes, requiring additional equipment like cutting or press devices.
Innovation Solution
A manufacturing method for OLED displays using a thin film encapsulation layer and pixel laminating film with acryl-based adhesive layers containing di-functional and hexa-functional UV oligomers, where the concentrations of these oligomers differ between layers, allowing for selective adhesion control through UV light irradiation to facilitate easy peeling of the laminating film from the peripheral areas without additional cutting or press devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If photolithography process is used for laminating film patterning, then the laminating film can be patterned, but the OLED display under the laminating film is damaged
Solution Approach 1:
The patent replaces the mechanical/chemical photolithography process with a UV-curable adhesive system. The adhesive layers with different UV oligomer concentrations are selectively cured using UV light irradiation through a photomask, allowing non-contact patterning that avoids damage to the OLED display while achieving the desired laminating film pattern.
Solution Approach 2:
The patent utilizes parameter changes in the UV oligomer concentrations (di-functional vs. hexa-functional) to control the curing behavior of different adhesive layers. By adjusting the concentration ratios, the adhesive layers exhibit different reactivity to UV light, enabling selective bonding and release without physical contact or harsh chemicals that could damage the display.
2Ease of manufacture
If laser cutting process or press process is used for laminating film patterning, then the laminating film can be patterned, but additional cutting or press devices are required which increases process time and cost
Solution Approach 1:
The patent employs a multi-functional UV curing system that integrates patterning, bonding, and release functions into a single process platform. The same UV irradiation equipment can selectively cure different adhesive layers at different stages, eliminating the need for separate laser cutting or pressing devices while reducing process time and equipment complexity.
Solution Approach 2:
The patent applies preliminary action by pre-configuring the adhesive layers with specific UV oligomer concentrations before assembly. This allows the adhesive properties to be predetermined, enabling subsequent selective curing and release operations without requiring additional processing equipment or steps during final assembly.
3Ease of manufacture
If conventional laminating film patterning processes are used, then the laminating film can be patterned, but pattern change due to model change of OLED display cannot be easily performed
Solution Approach 1:
The patent introduces dynamics into the patterning system by using a photomask that can be easily replaced or modified to match different OLED display models. The UV-curable adhesive system allows for flexible reconfiguration of patterns without requiring retooling or recalibration, enabling rapid adaptation to model changes while maintaining manufacturing simplicity.
Solution Approach 2:
The patent uses a photomask as a copying tool to transfer the desired laminating film pattern onto the adhesive layers. This copying mechanism allows for easy reproduction of different patterns by simply changing the photomask design, providing high adaptability to different OLED display models without complex reprogramming or reconfiguration.
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 method reduces process time and cost by allowing for simple and cost-effective patterning of the laminating film, enabling easy pattern changes without additional equipment, while maintaining protection of the OLED display.
Implementation Method 1
Each of the plurality of adhesive layers may contain an acryl-based adhesive, a di-functional UV oligomer, and a hexa-functional UV oligomer... radiating ultraviolet (UV) light on the laminating film that corresponds to the peripheral area of the substrate to decrease adhesion between the lower adhesive layer and the thin film encapsulation layer
Data Source
AI summary
A manufacturing method of an OLED display is provided. The method includes: forming an organic emission layer and a thin film encapsulation layer covering the organic emission layer on a substrate including a pixel area and a peripheral area; adhering a laminating film including a plurality of adhesive layers and an upper protective layer that covers an upper adhesive layer from among the adhesive layers on the thin film encapsulation layer, a lower adhesive layer from among the adhesive layers contacting the thin film encapsulation layer; radiating UV light on the laminating film that corresponds to the peripheral area of the substrate to decrease adhesion between the lower adhesive layer and the thin film encapsulation layer corresponding to the peripheral area; and peeling the laminating film corresponding to the peripheral area from the thin film encapsulation layer to maintain the laminating film that corresponds to the pixel area.