OLED Thin Film Encapsulation with Density-Graded Inorganic Layers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current OLED display manufacturing methods face challenges in achieving improved light efficiency, reduced manufacturing time and cost, and enhanced durability, while maintaining a longer lifespan.
Innovation Solution
The use of a thin film encapsulation layer with a first and second inorganic layer of different densities, formed through an ALD process, which includes an intermediate layer to reduce internal stress and improve flexibility, and are made from materials like aluminum oxide or titanium oxide, to encapsulate organic light emitting diodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thin film encapsulation layer with multiple inorganic layers of different densities is used, then light efficiency is improved and durability is enhanced, but manufacturing complexity increases
Solution Approach 1:
The encapsulation layer is divided into multiple inorganic sub-layers with different densities (first inorganic layer with higher density, second inorganic layer with lower density). This segmentation allows each layer to contribute differently to stress distribution and light extraction, improving overall durability and light efficiency while managing complexity through functional specialization.
Solution Approach 2:
The patent employs composite inorganic materials with different densities in a layered structure. The first inorganic layer uses a higher density material and the second inorganic layer uses a lower density material, creating a composite encapsulation system that optimizes both mechanical durability and optical performance.
2Stability of the object's composition
If intermediate layers are added between inorganic layers, then internal stress is reduced and flexibility is improved, but manufacturing time and cost increase
Solution Approach 1:
An intermediate layer is introduced between the first and second inorganic layers to act as a stress buffer. This intermediate layer has different mechanical properties that allow it to absorb and distribute internal stresses, preventing crack propagation and improving overall structural stability without requiring complex additional processing steps.
3Manufacturing precision
If multiple deposition processes are used to form different inorganic layers, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent controls the density of each inorganic layer by adjusting deposition parameters such as temperature, pressure, and deposition rate during the formation process. By precisely controlling these parameters, the first inorganic layer achieves higher density while the second inorganic layer achieves lower density, ensuring optimal stress distribution and light efficiency without requiring excessive processing steps.
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 light efficiency, reduces manufacturing time and cost, and increases the OLED display's durability and lifespan by minimizing damage from stress and maintaining image quality.
Implementation Method 1
formed through an ALD process
Data Source
AI summary
An organic light emitting diode (OLED) display includes: a substrate; an organic light emitting diode on the substrate; and a thin film encapsulation layer including a first inorganic layer having a first density on the substrate and a second inorganic layer having a second density on the first inorganic layer, the second density being different from the first density, and the organic light emitting diode being encapsulated between the thin film encapsulation layer and the substrate.