OLED Display Sealing with Thermosetting Adhesive and Getter Layer
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Solution Overview
Problem
Organic light emitting diode (OLED) displays are prone to deterioration due to exposure to moisture and oxygen, requiring effective sealing technologies to prevent external ingress and enhance display quality and lifespan.
Innovation Solution
A method involving the formation of a thermosetting adhesive layer with a getter receiving portion on a metal sheet, which includes a getter layer to absorb moisture and oxygen, and a roll-to-roll process for manufacturing, allowing for improved sealing and heat dissipation in large-sized OLED displays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing technologies are used for OLED displays, then manufacturing process is simpler, but moisture and oxygen permeation occurs leading to display deterioration
Solution Approach 1:
The sealing structure is divided into multiple functional layers: a barrier layer for moisture and oxygen blocking, an adhesive layer for bonding, and a getter layer for absorbing residual moisture and oxygen. This segmentation allows each layer to perform its specific function optimally while maintaining overall sealing reliability.
Solution Approach 2:
The patent employs composite material structures combining organic and inorganic layers. The barrier layer uses inorganic materials for superior moisture and oxygen resistance, while the adhesive layer uses organic materials for effective bonding. This composite approach achieves both protection and adhesion requirements.
2Area of stationary object
If large-sized OLED displays greater than 30 inches are manufactured using conventional methods, then display size is increased, but manufacturing costs increase and process failures occur
Solution Approach 1:
The getter layer is pre-formed and positioned in advance within the sealing structure before final assembly. This preliminary action ensures proper placement and maximizes moisture and oxygen absorption capacity, preventing display deterioration even in large-sized displays where sealing challenges are more pronounced.
Solution Approach 2:
The adhesive layer serves as an intermediary between the barrier layer and the display encapsulation structure. It ensures strong bonding while accommodating thermal expansion differences, preventing delamination and sealing failures in large-sized displays during manufacturing and operation.
3Ease of manufacture
If display unit is exposed to moisture and oxygen, then manufacturing process is simpler without sealing, but display function deteriorates
Solution Approach 1:
The getter layer creates an inert environment within the sealed display structure by actively absorbing moisture and oxygen. This internal inert atmosphere protection allows the display to maintain its functional lifespan without requiring complex external sealing processes, balancing manufacturing simplicity with long-term reliability.
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 prevents moisture and oxygen ingress, enhancing the display quality and lifespan of OLED displays while enabling the manufacturing of large-sized displays greater than 30 inches with reduced manufacturing costs and minimized process failures.
Implementation Method 1
hardening the thermosetting adhesive layer
Implementation Method 2
forming a getter layer at an external side of the display unit on the substrate
Data Source
AI summary
A method for manufacturing an OLED display according to an exemplary embodiment comprises: forming a thermosetting adhesive layer having a getter receiving portion on a metal sheet; forming a display unit including a plurality of pixels on a substrate; forming a getter layer at an external side of the display unit on the substrate; adhering the thermosetting adhesive layer and the metal sheet to the substrate so as to locate the getter layer in the getter receiving unit; and hardening the thermosetting adhesive layer. The forming of the thermosetting adhesive layer includes layering a solid thermosetting adhesive sheet which has been patterned so as to have the getter receiving portion on the metal sheet.