OLED Encapsulation with Interlocking Film Layers
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Solution Overview
Problem
Existing OLED encapsulation structures have a poor packaging effect and low light extraction efficiency due to misalignment of film layers when oscillated or bent, which affects the longevity and performance of OLED devices.
Innovation Solution
An OLED encapsulation structure with alternately stacked inorganic and organic film layers featuring complementary topographies, such as engaging slots and protrusions, to ensure precise contact and prevent misalignment, along with a buffer layer for enhanced sealing and light management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If film layers are stacked alternately with flat surfaces, then the structure is simple to manufacture, but the encapsulation effect deteriorates due to misalignment when oscillated or bent
Solution Approach 1:
The patent applies asymmetry by creating complementary topographies on adjacent film layers - one layer has protrusions while the adjacent layer has corresponding slots. This asymmetric design ensures that the layers interlock and cannot shift relative to each other during oscillation or bending, thereby preventing misalignment and improving encapsulation reliability without significantly complicating the manufacturing process.
2Reliability
If film layers are made with complementary topographies to prevent misalignment, then encapsulation effect improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent implements preliminary action by pre-forming the topographic features (protrusions and slots) on the film layers during the deposition process itself, rather than requiring post-deposition alignment procedures. The complementary topographies are built in during sequential layer deposition, ensuring automatic mechanical interlocking and eliminating the need for high-precision alignment operations after the layers are formed.
3Reliability
If film layers are stacked with flat surfaces, then light extraction efficiency is maintained, but encapsulation reliability deteriorates
Solution Approach 1:
The patent applies parameter changes by modifying the surface topology parameter of the film layers from flat to featuring complementary protrusions and slots. This change is integrated into the deposition process parameters, where the topographic features are formed during sequential layer deposition using controlled deposition conditions, thereby improving encapsulation reliability while maintaining manufacturing simplicity.
Data Source
AI summary
The present disclosure discloses an OLED encapsulation structure, a display device and a method for manufacturing an OLED encapsulation structure. The OLED encapsulation structure includes an OLED device and a plurality of film layers covering the OLED device. The plurality of film layers includes an inorganic layer and an organic layer stacked alternately, and contacting surfaces of any two film layers in contact with each other among the plurality of film layers include complementary topographies such that the any two film layers in contact with each other are stuck with each other.