OLED Panel Lateral Encapsulation with Segmented Barrier Walls
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Solution Overview
Problem
Existing encapsulation methods for flexible OLED displays fail to achieve a water vapor transmission rate (WVTR) less than 10−6 g/m2/day, leading to a shortened lifespan due to inadequate gas blocking capabilities.
Innovation Solution
A sideway encapsulation structure with at least two circumferential loops of barrier walls, a first inorganic blocking layer, an organic buffer layer, and a densification layer formed using inkjet printing and plasma enhanced chemical vapor deposition, creating a complicated path to retard water vapor and oxygen invasion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stacked film encapsulation is used for flexible OLED displays, then flexibility is maintained, but gas blocking capability is insufficient (WVTR > 10^-6 g/m2/day)
Solution Approach 1:
The encapsulation structure is segmented into multiple functional layers: inorganic barrier layers (first and second) provide gas blocking, while organic buffer layers and densification layers provide mechanical flexibility and structural support. This segmentation allows each layer to specialize in specific functions, achieving both high gas blocking capability and flexibility.
Solution Approach 2:
The patent employs composite material structure combining inorganic materials (for gas barrier properties) and organic materials (for flexibility and buffer properties). The combination of these materials with different properties creates an encapsulation structure that simultaneously achieves gas blocking capability below 10^-6 g/m2/day and maintains flexibility for flexible displays.
2Reliability
If conventional encapsulation methods are used, then manufacturing is simple, but encapsulation capability is insufficient to achieve WVTR < 10^-6 g/m2/day
Solution Approach 1:
The patent introduces a densification layer between the inorganic barrier layers, creating a multi-dimensional layered structure. This additional dimension in the encapsulation architecture provides enhanced gas blocking capability through multiple interfaces and pathways for moisture diffusion resistance, achieving WVTR < 10^-6 g/m2/day.
Solution Approach 2:
The organic buffer layer and densification layer act as intermediary layers between the inorganic barrier layers. These intermediary layers provide mechanical compliance, stress relief, and additional diffusion barriers, enhancing the overall encapsulation capability while allowing the inorganic layers to maintain their gas blocking function.
3Reliability
If simple encapsulation structure is used, then manufacturing is easier, but lateral side encapsulation is insufficient against water vapor and oxygen invasion
Solution Approach 1:
The patent uses thin film encapsulation with multiple organic and inorganic layers that conform to the OLED structure. The flexible organic buffer layers and densification layers provide effective lateral side encapsulation by conformally covering the OLED edges and providing continuous barrier paths, achieving superior gas blocking without requiring complex rigid encapsulation structures.
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 lateral side film encapsulation, effectively protecting the OLED device by increasing gas blocking capability and extending its lifespan while being suitable for flexible OLED panels.
Implementation Method 1
coating and forming an organic buffer layer on a portion of the first inorganic blocking layer that corresponds to the light emission area and coating and forming a densification layer on a portion of the first inorganic blocking layer that corresponds to an area between every two adjacent ones of the barrier walls
Implementation Method 2
depositing a first inorganic blocking layer of an entire surface to completely cover the OLED device and entirety of the barrier walls
Data Source
AI summary
The present invention provides an OLED panel fabrication method and an OLED panel. The OLED panel fabrication method of the present invention is such that at least two loops of spaced barrier walls are provided on an outer circumference of the OLED device and inkjet printing is applied to form, in sequence, an organic buffer layer between a first inorganic blocking layer and a second inorganic blocking layer at a location above a light emission area defined and delimited by the barrier walls and a loop of densification layer between the first inorganic blocking layer and the second inorganic blocking layer at a location above an area between two adjacent ones of the barrier walls so as to form a complicated path that retards invasion of water vapor and oxygen in a lateral side encapsulation structure to improve a lateral side film encapsulation effect thereby providing a film encapsulation structure having an increased gas blocking capability to effectively protect the OLED device, increase the life span of the OLED device, and suit the need of encapsulation of a flexible OLED panel. In addition, the fabrication method is easy to carry out.