Thermally Deposited Organic Protection Layer for OLED Packaging
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Solution Overview
Problem
Organic light emitting diodes (OLEDs) are prone to deterioration due to internal factors like oxygen from ITO electrodes and external factors such as humidity and ultraviolet radiation, which affects their lifespan, and existing packaging methods may damage the OLEDs during manufacturing.
Innovation Solution
An organic light emitting apparatus with a filling material between the diode substrate and encapsulation substrate, and an organic protection layer made of thermally depositable organic materials between the OLED unit and the filling material to prevent damage from external factors and ensure the OLED's integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a filling material is provided between the diode substrate and encapsulation substrate, then the OLED is protected from external factors, but the filling material may damage the organic light emitting unit
Solution Approach 1:
An organic protection layer is introduced as an intermediary between the filling material and the organic light emitting unit. This protection layer is formed by thermal decomposition of a thermally depositable organic material, creating a barrier that prevents the filling material from directly contacting and damaging the OLED while still allowing the filling material to provide its protective function against external factors.
Solution Approach 2:
The organic protection layer is formed in advance before the filling material is applied. By pre-forming this protective barrier on the OLED surface, the system ensures that when the filling material is subsequently introduced, it cannot cause damage to the organic light emitting unit, thus preventing harm before it occurs.
2Ease of manufacture
If existing packaging methods are used, then manufacturing is simplified, but the OLED may be damaged during manufacturing
Solution Approach 1:
The organic protection layer is formed on the OLED surface before the encapsulation and filling processes. This preliminary protective measure ensures that subsequent manufacturing steps involving filling materials do not compromise the OLED's integrity, while still maintaining the simplicity of the overall packaging process.
Solution Approach 2:
The thermally deposited organic material serves as a mediator between the manufacturing process and the OLED. It allows the filling material to be applied and positioned as needed while preventing direct harmful interactions, thus enabling simplified manufacturing without sacrificing device integrity.
3Ease of manufacture
If thermally depositable organic material is used for the protection layer, then manufacturing cost is reduced, but the material must be carefully selected to avoid damage
Solution Approach 1:
The invention changes the parameter of material deposition method to thermal decomposition, which allows for lower-cost organic materials to be used compared to other deposition techniques. By controlling the thermal decomposition process, the system achieves effective protection while using economically viable materials, though precise control of deposition parameters is required.
Solution Approach 2:
The protection layer formed by thermal decomposition provides localized protection exactly where needed on the OLED surface. The material properties and deposition characteristics can be optimized for specific regions, allowing careful selection and application of thermally depositable materials that match the requirements of different areas of the organic light emitting unit.
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 effectively minimizes damage from external factors and extends the lifespan of OLEDs by using a thermally deposited organic protection layer that protects the OLED unit from the filling material, resulting in improved durability and reduced manufacturing costs.
Implementation Method 1
an organic protection layer which is formed of at least one thermally depositable organic material and disposed between the organic light emitting unit and the filling material
Data Source
Figure 1
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Figure 3A~3B
AI summary
An organic light emitting apparatus and a method of manufacturing the same. The organic light emitting apparatus includes: a filling material between a diode substrate on which an organic light emitting unit is formed and an encapsulation substrate; and an organic protection layer that is interposed between the organic light emitting unit and the filling material and includes at least one thermally depositable organic material.