OLED Encapsulation Layer Carbon Content Adhesion
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Solution Overview
Problem
The existing encapsulation structures for organic light emitting diode (OLED) displays face issues with adhesion between inorganic and organic layers, leading to reliability concerns due to weak bonding, which compromises the barrier against moisture and oxygen, and requires additional plasma treatment processes increasing processing time.
Innovation Solution
An OLED display with an encapsulation layer having a multilayer structure of inorganic and organic layers, where the inorganic layer contains 0.2 wt % to 6.2 wt % carbon, improving adhesion and maintaining the barrier characteristic, formed using atomic layer deposition (ALD) with controlled carbon content through precursor management and plasma reaction parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thin film encapsulation structure with alternately laminated organic and inorganic layers is used, then the organic light emitting diode is protected from oxygen and moisture penetration, but the adhesion between inorganic and organic layers is weak causing detachment along interfaces
Solution Approach 1:
The patent applies parameter changes by controlling the carbon content in the inorganic layer within a specific range (0.2-6.2 wt%) to optimize both adhesion strength and barrier properties. This parameter optimization resolves the contradiction by finding the optimal composition that satisfies both protection and adhesion requirements simultaneously
Solution Approach 2:
The patent creates a composite inorganic layer containing carbon within the inorganic matrix, forming a composite material that combines the barrier properties of inorganic materials with the adhesion benefits of carbon content, thereby resolving the adhesion weakness while maintaining protection functionality
2Strength
If plasma treatment is performed before and after forming organic and inorganic layers to improve adhesion, then the adhesion between layers is enhanced, but the processing time is increased
Solution Approach 1:
The patent extracts and eliminates the separate plasma treatment steps from the manufacturing process by incorporating adhesion enhancement directly into the inorganic layer formation process through controlled carbon content, thereby reducing processing time while maintaining adhesion strength
Solution Approach 2:
The patent merges the adhesion enhancement function previously achieved by separate plasma treatment steps into the inorganic layer formation process itself by controlling carbon content during deposition, combining multiple functions into a single process step and reducing overall processing time
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
Enhances adhesion between inorganic and organic layers, reduces the occurrence of layer peeling and dark spot defects, and eliminates the need for separate plasma treatment processes, thereby improving the durability and efficiency of the OLED display manufacturing process.
Implementation Method 1
the inorganic layer serves to prevent oxygen or moisture from penetrating
Implementation Method 2
adhesion to the organic layer is improved
Implementation Method 3
formed using atomic layer deposition (ALD) with controlled carbon content
Implementation Method 4
controlled carbon content through precursor management and plasma reaction parameters
Data Source
AI summary
Disclosed are an organic light emitting diode display and a manufacturing method thereof, and, more particularly, an organic light emitting diode display which includes an encapsulation layer including an inorganic layer containing carbon at a level of about 0.2 wt % to about 6.2 wt % and an organic layer and a manufacturing method thereof.