OLED Encapsulation Sacrificial Layer Removal

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Solution Overview

Problem

Conventional organic light-emitting diode (OLED) display encapsulation structures suffer from reduced luminous efficiency due to the deposition of film layers on illuminating surfaces, which affect the appearance and luminosity of the display panel.

Innovation Solution

A display encapsulation structure and manufacturing method that involves disposing a sacrificial layer on a transparent cover, allowing the encapsulating film layer to be removed from the upper surface while remaining on the side surfaces, preventing interference with luminous efficiency and improving the encapsulation's luminous efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an atomic layer deposited (ALD) film layer is formed to encapsulate the entire display device, then the encapsulation effect is enhanced and moisture and oxygen isolation is improved, but the film layer is deposited on the illuminating surface of the display panel which affects the appearance and luminosity

Engineering Contradiction:

Improveencapsulation effectVSAvoidluminosity

Core Design Contradiction:

ReliabilityVSIllumination intensity

Solution Approach 1:

The encapsulation structure is segmented into different regions: the illuminating surface is kept free of film layers while the side surfaces and non-illuminating areas receive the encapsulating film layer. This is achieved by using a sacrificial layer that is selectively removed from the illuminating surface area, allowing the ALD film to be deposited only where needed for encapsulation without affecting the display's luminosity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The harmful film layer deposition on the illuminating surface is prevented by extracting or removing the sacrificial layer from that specific area before the encapsulating film layer is formed. This allows the encapsulation film to be applied to side surfaces while the illuminating surface remains clear, thus taking out the problematic film deposition from the light-emitting area.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If a sacrificial layer is disposed on the transparent cover and the encapsulating film layer is formed on the upper surface of the sacrificial layer, then complete encapsulation is achieved, but the film layer on the upper surface will affect the appearance and luminous efficiency when viewed from the front

Engineering Contradiction:

Improveencapsulation completenessVSAvoidappearance quality

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The sacrificial layer is disposed on the transparent cover before the encapsulating film layer is formed. This preliminary action creates a temporary structure that allows the encapsulation film to be applied to the upper surface for complete encapsulation. Afterward, the sacrificial layer is removed, taking the film layer with it from the upper surface, thus achieving complete encapsulation while maintaining appearance quality.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sacrificial layer serves as a temporary placeholder that is intentionally discarded after serving its purpose. It allows the encapsulation film to be deposited on the upper surface for complete encapsulation, and then it is removed along with the film layer from that area. The sacrificial layer is recovered or replaced with a clear structure that does not interfere with appearance or luminosity.

Inventive Principle:

Principle #34Discarding and recovering

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 method effectively prevents the encapsulating film layer from affecting the luminous efficiency of the display panel by removing it from the illuminating surface, thereby enhancing the display's luminous efficiency while maintaining moisture and oxygen isolation.

Implementation Method 1

an atomic layer deposited (ALD) film layer is formed to encapsulate the entirety

Methodology Applied

Scientific EffectAtomic layer deposition: Chemical Vapour Deposition

Implementation Method 2

removing the sacrificial layer to expose the transparent cover, and remaining the encapsulating film layer on the side surface of the display device encapsulation structure and the side surface of the transparent cover

Methodology Applied

Scientific Effect[inferred: sacrificial layer removal process]:

Data Source

PatentUS11329253B2Manufacturing method of display encapsulation structure by removing sacrificial layer to expose transparent cover

Publication Date: 2022.05.10 TCL CHINA STAR OPTOELECTRONICS TECHNOLOGY CO LTD

AI summary

A display encapsulation structure and a manufacturing method thereof are provided. The manufacturing method includes steps of providing a sacrificial layer, a display device encapsulation structure, and a transparent cover; providing an encapsulating film layer; and removing the sacrificial layer to expose the transparent cover. The encapsulating film layer is removed from the transparent cover plate when the sacrificial layer is removed, so as to avoid affecting luminous efficiency by the encapsulating film layer, thereby improving the luminous efficiency of the display encapsulation structure.