Hybrid Encapsulation Layer for Flexible OLED Displays

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Solution Overview

Problem

Existing organic light emitting display apparatuses face challenges in achieving effective water and oxygen cutoff while maintaining flexibility and reducing manufacturing costs, with current encapsulation structures being vulnerable to external impacts and requiring complex, costly processes.

Innovation Solution

An organic light emitting display apparatus utilizing a hybrid encapsulation layer formed from a block copolymer and functionalized graphene, which is applied through a simple coating process to provide enhanced water and oxygen barrier properties and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If encapsulation glass and frit layer are used to protect the organic light-emissive device, then water and oxygen penetration is prevented, but the display apparatus becomes vulnerable to external impact and cannot be made flexible

Engineering Contradiction:

Improveprotection from water and oxygenVSAvoidflexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent replaces rigid encapsulation glass with a flexible organic encapsulation layer comprising multiple sub-layers (first organic encapsulation layer, second organic encapsulation layer, and third organic encapsulation layer). These thin film structures provide the necessary barrier properties against water and oxygen while maintaining flexibility, enabling the display apparatus to be bent or folded without damage.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The encapsulation structure uses composite organic materials with different properties arranged in multiple layers. Each layer has specific characteristics (e.g., barrier properties, flexibility, adhesion) that complement the others, creating a composite structure that simultaneously achieves protection from water/oxygen and mechanical flexibility.

Inventive Principle:

Principle #40Composite materials

2Reliability

If encapsulation glass with frit layer is used, then water and oxygen cutoff is achieved, but the structure is vulnerable to external impact

Engineering Contradiction:

Improvewater and oxygen barrierVSAvoidresistance to external impact

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent employs thin film encapsulation layers that are inherently more impact-resistant than rigid glass structures. The flexible nature of the organic layers allows them to absorb and distribute impact forces throughout the structure rather than concentrating stress at specific points, thereby improving resistance to external impact while maintaining the water and oxygen barrier function.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The encapsulation structure is divided into multiple separate organic layers instead of using a single rigid glass piece. This segmentation allows each layer to independently respond to external forces, providing better impact resistance while collectively maintaining the barrier function against water and oxygen penetration.

Inventive Principle:

Principle #1Segmentation

3Reliability

If complex encapsulation structures are used to prevent water and oxygen penetration, then protection is improved, but manufacturing cost and process complexity increase

Engineering Contradiction:

Improveprotection from water and oxygenVSAvoidmanufacturing process simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple encapsulation functions into an integrated organic encapsulation structure that can be formed using the same manufacturing process steps as the existing display device fabrication. The organic encapsulation layers are deposited using standard thin film deposition techniques already employed in the industry, merging the encapsulation process with the existing manufacturing flow and avoiding the need for separate complex encapsulation processes.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the material parameter from inorganic glass to organic materials, which fundamentally alters the deposition process parameters. Organic materials can be deposited at lower temperatures and using simpler processes compared to glass encapsulation, thereby simplifying the manufacturing process while maintaining effective water and oxygen barrier properties.

Inventive Principle:

Principle #35Parameter changes

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 prevents water and oxygen penetration, enhances flexibility, and simplifies the manufacturing process, reducing costs and improving the reliability and service life of the display apparatus.

Implementation Method 1

Methodology Applied

Scientific EffectBarrier properties:

Implementation Method 2

Methodology Applied

Scientific EffectFlexibility: Elasticity

Data Source

PatentUS9502688B2Organic light emitting display apparatus and method of manufacturing the same

Publication Date: 2016.11.22 LG DISPLAY CO LTD

AI summary

Provided are an organic light emitting display apparatus and a method of manufacturing the same. The organic light emitting display apparatus includes: a thin film transistor (TFT) substrate including a plurality of thin film transistors, an organic light-emissive device on the TFT substrate, and an encapsulation layer on the TFT substrate and the organic light-emissive device, the encapsulation layer being configured to cover the organic light-emissive device, the encapsulation layer including a hybrid material including: a block copolymer, and functionalized graphene.