Inorganic Layer Encapsulation for OLED Moisture Barrier

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Solution Overview

Problem

In display panels, moisture and oxygen intrusion along the substrate, organic filling layer, planarization layer, and pixel defining layer corrodes the organic light emitting device, leading to pixel shrinkage and reduced service life.

Innovation Solution

An inorganic layer is introduced between the planarization layer and the pixel defining layer, forming an encapsulation structure with the first interlayer dielectric layer and planarization layer to block moisture and oxygen, preventing corrosion of the organic light emitting device from the bottom.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a thin-film package is provided for moisture and oxygen barrier, then moisture and oxygen intrusion from upper layers is blocked, but moisture and oxygen can still erode the light emitting layers through bottom structures

Engineering Contradiction:
Improvemoisture and oxygen barrier performanceVSAvoidprotection against bottom intrusion
Core Design Contradiction:
Object-affected harmful factorsVSReliability

Solution Approach 1:

The encapsulation structure is divided into multiple segments: the first interlayer dielectric layer forms a first encapsulation structure, the planarization layer forms a second encapsulation structure, and the inorganic layer forms a third encapsulation structure. This segmented approach creates multiple barrier layers that collectively prevent moisture and oxygen intrusion from both upper and bottom directions, resolving the contradiction between blocking top intrusion and preventing bottom erosion.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The encapsulation structure combines multiple materials with different properties: the first interlayer dielectric layer (inorganic), the planarization layer (organic), and the inorganic layer (inorganic). This composite structure leverages the complementary properties of different materials to achieve comprehensive moisture and oxygen barrier performance, protecting against intrusion from all directions.

Inventive Principle:
Principle #40Composite materials

2Strength

If an organic filling layer is provided below the bending area to relieve bending stress, then bending stress is relieved, but moisture and oxygen barrier performance becomes poor

Engineering Contradiction:
Improvebending stress reliefVSAvoidmoisture and oxygen barrier performance
Core Design Contradiction:
StrengthVSObject-affected harmful factors

Solution Approach 1:

The solution moves from a single-layer approach to a multi-dimensional layered structure. The encapsulation structure extends vertically through multiple layers (first interlayer dielectric layer, planarization layer, inorganic layer), creating a three-dimensional barrier system that maintains moisture and oxygen protection even in the bending area where the organic filling layer is present.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The inorganic layer acts as an intermediary barrier between the organic filling layer (which relieves bending stress but has poor barrier performance) and the light emitting layer (which needs protection). This intermediary layer provides the necessary moisture and oxygen protection while allowing the organic filling layer to perform its stress relief function.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Adaptability or versatility

If the thin-film transistor and organic light emitting device are disposed in the display area, then full screen design is achieved, but the organic light emitting device is vulnerable to moisture and oxygen intrusion along the substrate and layers

Engineering Contradiction:
Improvefull screen design capabilityVSAvoidmoisture and oxygen intrusion
Core Design Contradiction:
Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The encapsulation structure serves multiple functions simultaneously: it provides mechanical support for the thin-film transistor and organic light emitting device, enables full screen design by being integrated into the display area, and provides comprehensive moisture and oxygen protection. The multi-functional nature of the encapsulation structure resolves the contradiction between achieving full screen design and preventing harmful factor intrusion.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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 inorganic layer effectively prevents moisture and oxygen intrusion, enhancing the service life of the organic light emitting device by forming a robust encapsulation structure.

Implementation Method 1

an inorganic layer disposed between the planarization layer and the pixel defining layer and configured to block moisture and oxygen

Methodology Applied
Scientific EffectBarrier effect:

Data Source

PatentUS11217642B2Display panel, manufacturing method thereof, and display device
Publication Date: 2022.01.04 WUHAN CHINA STAR OPTOELECTRONICS SEMICONDUCTOR DISPLAY TECHNOLOGY CO LTD
  • US11217642B2 patent drawing
  • US11217642B2 patent drawing
  • US11217642B2 patent drawing

AI summary

A display panel and a method of manufacturing the display panel are provided. The display panel includes an array substrate, a planarization layer, a pixel defining layer, an organic light emitting device, and an inorganic layer disposed between the planarization layer and the pixel defining layer to block moisture and oxygen. An encapsulation structure of the array substrate is cooperatively formed by a combination of a first interlayer dielectric layer contained in a thin-film transistor, the planarization layer, and the inorganic layer.