OLED Composite Substrate Interlaced Inorganic Organic Layers Pinhole Reduction
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Solution Overview
Problem
Conventional OLED display panels face issues with moisture and oxygen penetration due to pinholes in thin inorganic film layers, leading to reduced luminous efficiency, black spots, and peeling of film layers, especially when subjected to bending stress.
Innovation Solution
A composite substrate structure with interlaced inorganic and organic layers, including a silicon nitride barrier layer and grid-like organic structures, enhances bonding strength and reduces pinholes, while the encapsulation layer effectively blocks moisture and oxygen, and distributes bending stress to prevent cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of inorganic film layers is increased to improve moisture and oxygen blocking, then the blocking ability is improved, but the bendability of the display panel deteriorates due to excessive stress
Solution Approach 1:
The patent employs a composite film structure consisting of alternating inorganic layers (silicon nitride, silicon oxide) and organic material structures. This composite design combines the moisture and oxygen blocking properties of inorganic materials with the flexibility of organic materials, achieving both protection and bendability. The organic material structures fill gaps and provide flexibility while the inorganic layers provide barrier functionality.
Solution Approach 2:
The patent applies different materials with specific properties at different locations within the film stack. The inorganic layers are positioned where moisture and oxygen blocking is most critical, while organic material structures are placed to provide flexibility and stress relief. This localized optimization allows the film structure to simultaneously achieve blocking and bendability.
2Reliability
If the thickness of inorganic film layers is increased to improve moisture and oxygen blocking, then the blocking ability is improved, but the film layers are more prone to peeling due to poor interface bonding
Solution Approach 1:
The composite structure of inorganic and organic materials creates multiple interfaces that enhance overall bonding strength. The organic material structures act as bonding layers between inorganic layers, preventing peeling. This composite approach distributes stress across multiple interfaces rather than relying on single thick inorganic layers.
Solution Approach 2:
The organic material structures serve as intermediary layers between the inorganic barrier layers. These intermediary organic layers improve interface bonding by providing compatible surfaces for adhesion, preventing direct contact between incompatible inorganic layers and reducing peeling tendency.
3Adaptability or versatility
If thin inorganic film layers are used to maintain bendability, then the display panel can be bent, but moisture and oxygen easily penetrate through pinholes
Solution Approach 1:
The patent uses a composite structure where thin inorganic layers provide flexibility and bendability while organic material structures fill pinholes and gaps. The organic materials complement the thin inorganic layers by providing additional barrier functionality without compromising flexibility, achieving both thinness and effective blocking.
Solution Approach 2:
The patent addresses pinhole formation by using organic material structures that fill and seal the porous defects in thin inorganic layers. The organic materials create a more complete barrier by occupying the voids and pinholes that would otherwise allow moisture and oxygen penetration, effectively converting the porous structure into a denser barrier.
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 significantly improves moisture and oxygen blocking, reduces peeling between layers, and enhances the OLED display panel's durability and bendability by creating a strong, compact film structure with reduced pinhole incidence and effective stress distribution.
Implementation Method 1
moisture or oxygen easily passes through the pinholes or other microstructures of the nanometer-thick inorganic film layer
Implementation Method 2
an interface bonding between the inorganic film layer and the organic film layer is poor
Implementation Method 3
distributes bending stress to prevent cracking
Data Source
AI summary
An organic light-emitting diode (OLED) display panel including a composite substrate including a first substrate, a barrier layer, a plurality of inorganic layers each interlaced therein with an organic material structure, and a second substrate interlaced therein with an organic material structure; a buffer layer disposed on the composite substrate; a thin film transistor layer disposed on the buffer layer; an OLED device layer disposed on the thin film transistor layer; and an encapsulation layer disposed on the OLED device layer.