OLED Blocking Member Encapsulation for Moisture Protection

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Solution Overview

Problem

Organic light emitting diodes (OLEDs) have a reduced lifespan due to exposure to moisture and air, which damages the organic light emitting layer, leading to decreased performance and longevity.

Innovation Solution

A display device is designed with a blocking member comprising a first and second blocking layer, formed on substrates, to prevent exposure of the light emitting element to moisture and air, using materials like thermosetting or photocurable resins, and applying pressure to combine the substrates securely.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the organic light emitting layer is exposed to moisture or air, then the OLED can be manufactured and operated, but the lifespan of the OLED is reduced due to damage to the organic light emitting layer

Engineering Contradiction:
ImprovelifespanVSAvoidexposure to moisture and air
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies the inert atmosphere principle by creating a sealed encapsulation structure that prevents the organic light emitting layer from contacting harmful environmental factors such as moisture and air. The blocking member with curing layers forms a protective barrier that maintains an inert environment around the sensitive OLED components, thereby extending lifespan without affecting operational functionality.

Inventive Principle:
Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The patent employs flexible blocking layers (first and second blocking layers) that are formed on substrates and cured to create a protective film structure. These thin film layers encapsulate the organic light emitting layer, providing protection against moisture and air penetration while maintaining the flexibility needed for OLED device structure.

Inventive Principle:
Principle #30Flexible shells and thin films

2Reliability

If blocking layers are formed on substrates to protect the light emitting element, then protection from moisture and air is achieved, but the device structure becomes more complex

Engineering Contradiction:
Improveprotection from environmental exposureVSAvoidstructure
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the blocking structure into multiple functional layers: a first blocking layer formed on a first substrate, and a second blocking layer formed on a second substrate. These segmented layers are then assembled together with the light emitting element between them, creating a modular protection system that provides comprehensive environmental barrier while maintaining manufacturing flexibility.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent implements the nesting principle by placing the light emitting element between the first and second blocking layers, which are themselves formed on separate substrates. The blocking layers are cured to form encapsulating shells that nest around the sensitive organic layer, creating a nested protective structure where each layer serves a specific protective function.

Inventive Principle:
Principle #7Nested doll (Nesting)

3Reliability

If pressure is applied to combine the substrates securely, then the blocking member effectively seals the light emitting element, but the manufacturing process becomes more complex

Engineering Contradiction:
Improvesealing effectivenessVSAvoidmanufacturing process
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by forming and curing the first blocking layer on the first substrate before assembly, and forming the second blocking layer on the second substrate before assembly. This preliminary preparation of the blocking layers ensures they are ready to provide immediate protection upon assembly, reducing the need for complex post-assembly processing while maintaining effective sealing.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent utilizes phase transitions through the curing process of the blocking layers. The blocking layers are applied in a uncured state, allowing for flexible assembly, and then cured (through UV exposure or other curing mechanisms) to transition to a solid, sealed state that provides effective environmental barrier. This phase transition enables simplified manufacturing while achieving reliable sealing.

Inventive Principle:
Principle #36Phase transitions

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 solution effectively increases the lifespan of OLEDs by protecting the light emitting element from environmental exposure, enhancing durability and maintaining display quality.

Implementation Method 1

The first blocking layer is cured. A second blocking layer is formed on a second substrate. The first substrate having the first blocking layer is assembled with the second substrate having the second blocking layer such that the first blocking layer faces the second blocking layer. Then, the second blocking layer is cured to form a blocking member that combines the first and second substrates.

Methodology Applied
Scientific EffectCuring: Photopolymerisation

Implementation Method 2

The first and second substrates are assembled with each other under a first pressure such that the first blocking layer of the first substrate faces the second blocking layer of the second substrate. The first and second blocking layers are cured under a second pressure that is higher than the first pressure.

Methodology Applied
Scientific EffectPressure: Pressure Increase

Data Source

PatentUS7915822B2Display device and method and apparatus for manufacturing the same
Publication Date: 2011.03.29 SAMSUNG DISPLAY CO LTD
  • US7915822B2 patent drawing
  • US7915822B2 patent drawing
  • US7915822B2 patent drawing

AI summary

A display device includes a first substrate, a second substrate and a blocking member. The first substrate has a light emitting element. The second substrate faces the first substrate. The blocking member is arranged between the first and second substrates. The blocking member includes a first blocking layer and a second blocking layer.