OLED Waterproof Anti-Reflective Packaging Layer

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Solution Overview

Problem

Existing OLED devices face issues with low light output due to total internal reflection and are prone to degradation from water vapor and oxygen, leading to increased costs and reduced service life, while achieving both waterproof and anti-reflection effects with a small overall thickness is challenging.

Innovation Solution

An OLED apparatus with an anti-reflection layer made of an organic material containing inorganic nanoparticles, featuring a convex-concave microstructure and surface modification, is used outside the upper flexible substrate, enhancing both adhesive force and light transmittance, and employing a plasma-chemical vapor deposition process to improve waterproof and anti-reflection performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional packaging layer is used to protect OLED from water vapor and oxygen, then waterproofing is improved, but the overall thickness increases and light output is reduced due to total internal reflection

Engineering Contradiction:
Improvewaterproof performanceVSAvoidoverall thickness
Core Design Contradiction:
ReliabilityVSLength of stationary object

Solution Approach 1:

The patent uses a composite packaging layer comprising an organic material layer and an inorganic material layer. The organic layer provides flexibility and baseline protection, while the inorganic layer (such as aluminum oxide or silicon oxide) provides superior waterproof and oxygen barrier properties. This composite structure achieves enhanced protection without requiring excessive thickness, as each layer contributes its strengths to create an effective barrier system.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent employs thin film structures for the packaging layer, utilizing advanced deposition techniques to create ultra-thin inorganic barrier layers (e.g., alternating layers of organic and inorganic materials with total thickness in the micrometer range). These thin films provide effective waterproof and oxygen protection while maintaining flexibility and minimizing overall device thickness, avoiding the bulkiness of conventional packaging solutions.

Inventive Principle:
Principle #30Flexible shells and thin films

2Reliability

If a conventional packaging layer is used to protect OLED from water vapor and oxygen, then waterproofing is improved, but light output is reduced due to total internal reflection at interfaces with different refractive indexes

Engineering Contradiction:
Improvewaterproof performanceVSAvoidlight output
Core Design Contradiction:
ReliabilityVSIllumination intensity

Solution Approach 1:

The patent applies an anti-reflective coating on the outer surface of the packaging layer. This coating is designed with specific optical properties (refractive index gradient or matched to surrounding media) to reduce total internal reflection at interfaces. By optimizing the optical characteristics of the packaging structure, light extraction efficiency is improved, allowing more photons to escape without being trapped by reflective interfaces, thus enhancing overall light output while maintaining waterproof protection.

Inventive Principle:
Principle #32Color changes

3Power

If the cathode uses active metals like aluminum, magnesium, or calcium to achieve low work function for electron injection, then electrical performance is improved, but the service life is reduced due to reactions with penetrating water vapor

Engineering Contradiction:
Improveelectron injection efficiencyVSAvoidservice life
Core Design Contradiction:
PowerVSDuration of action of stationary object

Solution Approach 1:

The patent employs a composite packaging structure with multiple layers including inorganic barrier layers (such as aluminum oxide, silicon oxide) that provide superior resistance to water vapor and oxygen penetration. This multi-layer composite barrier effectively isolates the reactive cathode metals from environmental moisture, preventing degradation reactions while allowing the cathode to maintain its low work function properties for efficient electron injection throughout the extended service life.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The packaging layer creates an inert protective environment around the cathode by providing a hermetic barrier against water vapor and oxygen. The inorganic material layers (e.g., aluminum oxide, silicon oxide) form chemically stable, impermeable barriers that effectively isolate the reactive metals from environmental contaminants, maintaining a protected atmosphere that prevents oxidation and degradation reactions, thereby extending device lifetime.

Inventive Principle:
Principle #39Inert atmosphere (Inert environment)

4Duration of action of stationary object

If a waterproof packaging layer is added to protect from water vapor and oxygen, then service life is improved, but production cost increases due to additional materials and processes

Engineering Contradiction:
Improveservice lifeVSAvoidproduction cost
Core Design Contradiction:
Duration of action of stationary objectVSEase of manufacture

Solution Approach 1:

The patent integrates the waterproof packaging function directly into the device structure by combining the packaging layer with the flexible substrate and other functional layers into a unified multi-layer structure. This integration eliminates the need for separate, additional waterproofing components, reducing material costs and simplifying the manufacturing process while still providing comprehensive protection against water vapor and oxygen to extend service life.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent uses composite material structures where inorganic barrier layers are deposited directly onto organic layers in an integrated manufacturing process. This approach leverages existing deposition techniques to create multi-functional layers that simultaneously provide structural support, flexibility, and waterproof protection, avoiding the need for separate waterproofing components and reducing overall production complexity and cost.

Inventive Principle:
Principle #40Composite materials

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 light output by 20-50% and improves the waterproof effect, maintaining a small overall thickness while ensuring both waterproof and anti-reflection properties, thus extending the service life and reducing production costs.

Implementation Method 1

Since interfaces between respective layers of the OLED have different refractive indexes, when light passes through these interfaces, with the occurrence of total internal reflection, photons finally exiting the surface of glass account for only 20% of a total amount of the photons

Methodology Applied
Scientific EffectTotal internal reflection: Total Internal Reflection

Implementation Method 2

Since interfaces between respective layers of the OLED have different refractive indexes, when light passes through these interfaces

Methodology Applied
Scientific EffectRefraction: Refraction

Implementation Method 3

a layer of inorganic nanoparticles is provided on a surface of the anti-reflection layer

Methodology Applied
Scientific EffectLight scattering: Scattering

Implementation Method 4

surfaces of the inorganic nanoparticles are modified by a coupling agent

Methodology Applied
Scientific EffectChemical bonding: Chemical Bonding

Implementation Method 5

employing a plasma-chemical vapor deposition process

Methodology Applied
Scientific EffectChemical vapor deposition: Chemical Vapour Deposition

Data Source

PatentUS10079367B2Waterproof and anti-reflective flexible OLED apparatus and method for manufacturing the same
Publication Date: 2018.09.18 BOE TECHNOLOGY GROUP CO LTD
  • US10079367B2 patent drawing
  • US10079367B2 patent drawing
  • US10079367B2 patent drawing

AI summary

The present disclosure relates to an Organic Light-Emitting Diode (OLED) apparatus and a method for manufacturing the same. The OLED apparatus comprises an OLED device, a device packaging layer, an upper flexible substrate, and a lower flexible substrate, wherein an anti-reflection layer is arranged outside the upper flexible substrate, and a layer of inorganic nanoparticles is provided on a surface of the anti-reflection layer. Using the technical solution of the present disclosure, an OLED apparatus which has both waterproof and anti-reflection effects and a small overall thickness is obtained.