OLED Panel Lamination Using Expandable Elements

Solution Overview

Problem

Existing methods for sealing organic light-emitting diode (OLED) displays with protective layers often result in bubbles and defects due to ineffective adhesion between the capping layer and the OLED materials, which compromises the moisture-proof seal.

Innovation Solution

A method and apparatus utilizing independently controlled expandable elements to precisely position and adhere a protective panel to an OLED assembly, ensuring full contact and minimizing adhesive defects by applying adhesive to one or both panels and using a fixture with inflatable elements to sequentially bring edges into contact under controlled pressure and vacuum conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive is applied to bond protective layer to OLED assembly, then adhesion is achieved, but bubbles and defects form in the adhesive interface

Engineering Contradiction:

Improveadhesion reliabilityVSAvoidbubbles and defects in adhesive interface

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies adhesive to the protective layer before bonding to the OLED assembly. This preliminary application allows the adhesive to be properly positioned and distributed on the protective layer surface, enabling complete coverage and preventing air entrapment during the bonding process, thereby eliminating bubbles and defects in the adhesive interface.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces a protective layer as an intermediary component between the adhesive and the OLED assembly. The protective layer serves as a mediator that receives the adhesive application and facilitates proper bonding to the OLED assembly, ensuring reliable adhesion while preventing direct contact defects between the adhesive and the OLED materials.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If adhesive is applied to bond protective layer to OLED assembly, then sealing is achieved, but manufacturing defects occur

Engineering Contradiction:

Improvesealing reliabilityVSAvoidadhesive interface quality

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies adhesive to the protective layer before bonding to the OLED assembly. This preliminary application allows the adhesive to be properly positioned and distributed on the protective layer surface, enabling complete coverage and preventing air entrapment during the bonding process, thereby eliminating bubbles and defects in the adhesive interface.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent controls the bonding process by adjusting parameters such as pressure application timing and magnitude. Pressure is applied progressively during the bonding process to ensure complete adhesive contact while preventing air entrapment, thereby achieving high manufacturing precision and eliminating defects in the adhesive interface.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If known bonding processes are used, then protective layer is adhered to OLED assembly, but bubbles form in the adhesive layer

Engineering Contradiction:

Improvebonding process simplicityVSAvoidbubbles in adhesive layer

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent applies adhesive to the protective layer before bonding to the OLED assembly. This preliminary application allows the adhesive to be properly positioned and distributed on the protective layer surface, enabling complete coverage and preventing air entrapment during the bonding process, thereby eliminating bubbles and defects in the adhesive interface.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces a protective layer as an intermediary component between the adhesive and the OLED assembly. The protective layer serves as a mediator that receives the adhesive application and facilitates proper bonding to the OLED assembly, ensuring reliable adhesion while preventing direct contact defects between the adhesive and the OLED materials.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 approach eliminates bubbles in the adhesive layer and provides a reliable, precise adhesion method for protective layers on OLED assemblies, enhancing the moisture-proof seal and reducing manufacturing defects.

Implementation Method 1

The expandable elements are further selectively expanded so that the adhesive fully contacts the first and second panels

Methodology Applied

Scientific EffectPressure: Pressure Increase

Implementation Method 2

an adhesive is applied to a face of at least one of the first and second panels

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS7435311B1Panel-to-panel lamination method for improved uniformity

Publication Date: 2008.10.14 ROCKWELL COLLINS INC

AI summary

A method of adhering a first panel, such as an OLED assembly, to a second panel, such as a protective cover plate, is disclosed. An adhesive is applied to a face of at least one of the first and second panels. The first panel is positioned to be responsive to movement of any of a plurality of independently controlled expandable elements. The second panel is held adjacent the first panel. At least one of the expandable elements is selectively expanded so that a first edge of the first panel contacts a first edge of the second panel. The expandable elements are further selectively expanded so that the adhesive fully contacts the first and second panels.