OLED Lighting Apparatus Anti-Scratch Passivation Layer
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Solution Overview
Problem
Organic light emitting diodes (OLEDs) are prone to damage during pulse aging due to scratches and particles, which affects production yield and reliability, especially when the substrate is wound or unwound in a high vacuum environment.
Innovation Solution
A lighting apparatus design with a second passivation layer made of organic or gas-permeable inorganic material that covers the organic light emitting layer and second electrode, acting as an anti-scratch layer and encapsulating layer, preventing moisture introduction and protecting the OLED from damage during substrate handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the substrate is wound or unwound during pulse aging to move the substrate to a p-aging chamber, then the aging process can be performed, but the exposed surface of the organic light emitting diode may be damaged due to scratches or particle contact
Solution Approach 1:
A protection layer is formed on the surface of the organic light emitting diode before the substrate is wound or unwound for pulse aging. This preliminary protective measure ensures that the vulnerable surface is shielded before any handling operations occur, preventing scratches and particle damage during the substrate movement to the p-aging chamber
Solution Approach 2:
The protection layer acts as a cushioning barrier that absorbs mechanical stresses and prevents direct contact between the vulnerable OLED surface and external particles or scratching surfaces during substrate handling operations
2Ease of operation
If the cathode electrode has a small thickness to allow substrate winding, then flexibility is improved, but the protective capability against scratches is reduced
Solution Approach 1:
The protective function is segmented from the cathode electrode by adding a separate protection layer. This allows the cathode electrode to maintain its small thickness for substrate winding flexibility, while the dedicated protection layer provides the necessary scratch resistance and surface protection
Solution Approach 2:
The protection layer serves as an intermediary between the vulnerable OLED structure and the external environment during substrate handling. It mediates the mechanical stresses and prevents direct interaction between the thin cathode electrode and scratching surfaces or particles
3Manufacturing precision
If multiple deposition chambers are used to maintain high vacuum for each thin film deposition, then deposition quality is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
Multiple deposition chambers are merged into a single multi-functional chamber that can sequentially perform different deposition tasks. The chamber maintains high vacuum conditions for all thin film depositions (organic light emitting layer, cathode electrode, protection layer) without requiring separate chambers, thereby reducing device complexity while preserving deposition quality
Solution Approach 2:
The deposition chamber is designed with universal functionality to handle multiple types of thin film depositions. By equipping the single chamber with appropriate deposition tools and capabilities, it can perform the work of multiple specialized chambers, reducing overall system complexity while maintaining high vacuum deposition quality for all layers
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 enhances the resistance to pressing pressure and prevents damage during pulse aging, improving production yield and reducing fabrication costs while ensuring reliability and uniform light emission.
Implementation Method 1
an organic light emitting diode part (101) comprising a first electrode (116) and a second electrode (126) disposed on a substrate (110), and an organic light emitting layer (130) disposed between the first electrode (116) and the second electrode (126)
Implementation Method 2
a second passivation layer (115b) made of an organic material or a gas-permeable inorganic material formed to cover the organic light emitting layer (130) and the second electrode (126) of the lighting portion (EA)
Data Source
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AI summary
A lighting apparatus (100) using an organic light emitting diode according to the present disclosure is configured such that a substrate is planarized by forming an anti-scratch layer (115b) on a cathode electrode (126) to fully cover the cathode electrode. The present disclosure having such configuration can uniformly maintain pressing pressure by virtue of the anti-scratch layer even while winding or unwinding the substrate for pulse aging, thereby preventing damages due to scratches or particles.