Non-Conformal Barrier Layer for OLED Moisture Isolation
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Solution Overview
Problem
Conventional OLED packaging technologies face challenges in minimizing OLED size due to misalignment issues during the organic layer coating process, which affects the display's moisture resistance and product life, and struggles to effectively isolate the organic electroluminescent component from moisture and water vapor.
Innovation Solution
The implementation of a non-conformal barrier layer design, where the first barrier layer's orthogonal projection area is larger than the organic light emitting diode, and the second barrier layer's area is larger than the first, with specific material choices like acrylic polymer and silicon nitride, to protect the OLED from moisture and solvent damage while allowing for complete coverage and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the boundary of the organic layer is designed to extend from that of OLED by maximum distance of misalignment to avoid incomplete coverage, then the reliability of moisture protection is improved, but the area of OLED increases and miniaturization becomes difficult
Solution Approach 1:
The barrier layer is divided into multiple segments with different extension distances from the OLED boundary in different directions. Instead of uniformly extending the barrier layer by the maximum misalignment distance in all directions, the patent segments the barrier layer into regions with different extension distances, optimizing both coverage and area.
Solution Approach 2:
Different regions of the barrier layer have different local qualities in terms of extension distance from the OLED boundary. The barrier layer is designed with varying thickness and extension characteristics in different areas to match the local misalignment requirements, rather than applying a uniform extension distance throughout.
2Ease of manufacture
If conventional spin coating and lithography processes are used for organic layer patterning, then ease of manufacture is improved, but manufacturing precision deteriorates due to misalignment between substrate and mask aligner
Solution Approach 1:
The barrier layer is designed with pre-calculated extension distances from the OLED boundary in different directions, anticipating potential misalignment issues before they occur. This preliminary design of asymmetric extension distances compensates for expected alignment errors in the spin coating and lithography processes.
Solution Approach 2:
The barrier layer is designed with asymmetric extension distances from the OLED boundary in different directions. Instead of a symmetric uniform extension, the patent employs asymmetric extension patterns that account for directional misalignment tendencies in the manufacturing process, improving both precision and ease of manufacture.
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
This design enhances moisture isolation, protects the OLED from defects, and allows for miniaturization of the OLED display by reducing the area of the barrier layer, thereby extending product life and improving display quality.
Implementation Method 1
the package material for OLED needs not only good abrasion resistance and high thermal conductivity, but also good isolation character from moisture and water vapor
Implementation Method 2
The organic layer is coated on the substrate by spin coating
Data Source
AI summary
An organic light emitting diode (OLED) display includes a substrate, an organic light emitting diode, and a first barrier layer. The organic light emitting diode is disposed on the substrate, in which the projection of the organic light emitting diode on the substrate has a first profile. The first barrier layer is disposed on the organic light emitting diode, in which the projection of the first barrier layer on the substrate has a second profile. The first profile is non-conformal with the second profile.