Optoelectronic Component Segmented Encapsulation

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Solution Overview

Problem

The production of top-emitting OLEDs is hindered by the need for additional process steps and potential damage from outgassing substances, particularly when using a bottom thin film encapsulation layer, which requires laser ablation for electrical contact establishment.

Innovation Solution

An optoelectronic component design featuring an electrically conductive layer, an electrically insulating layer, and an electrically weakly conductive encapsulation layer allows for direct electrical contact between the second electrode and the conductive layer without intermediate layers, eliminating the need for laser ablation and preventing harmful substances from reaching the organic functional layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an electrically insulating encapsulation layer is used to prevent outgassing damage, then reliability is improved, but device complexity increases due to the need for additional laser ablation process steps

Engineering Contradiction:

Improveprotection against outgassing damageVSAvoidprocess steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The encapsulation layer is segmented into two distinct functional zones: an electrically insulating region (first region) that protects against outgassing, and an electrically conductive region (second region) that enables direct electrical contact. This segmentation eliminates the need for laser ablation while maintaining both protection and conductivity functions separately within the same layer structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the encapsulation layer are assigned different electrical properties: the first region has electrical insulation properties to block outgassing pathways, while the second region has electrical conductivity properties to allow current flow. This local differentiation of material properties resolves the contradiction by providing both protection and conductivity where needed without requiring additional process steps.

Inventive Principle:

Principle #3Local quality

2Reliability

If a bottom TFE is used to prevent contamination, then reliability is improved, but productivity decreases due to additional manufacturing steps

Engineering Contradiction:

Improvecontamination preventionVSAvoidproduction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The encapsulation layer merges two previously separate functions into a single integrated structure: contamination protection (through the insulating first region) and electrical contact establishment (through the conductive second region). This merging eliminates the need for separate laser ablation steps, thereby improving productivity while maintaining reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The encapsulation layer serves multiple functions simultaneously: it acts as a barrier against outgassing and contamination in its first region, while also serving as an electrical contact medium in its second region. This multi-functionality reduces the number of manufacturing steps required, directly improving production efficiency without sacrificing protective functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If an electrically insulating layer is placed in direct contact with the conductive substrate, then manufacturing is simplified, but harmful outgassing substances can damage the OLED

Engineering Contradiction:

Improvelayer arrangementVSAvoidoutgassing damage

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The encapsulation layer is segmented into a first region with electrical insulation properties positioned between the conductive substrate and the OLED, and a second region with electrical conductivity properties. This segmentation allows the insulating first region to block outgassing pathways while maintaining the simplified direct-contact manufacturing approach.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first region of the encapsulation layer acts as an intermediary barrier between the conductive substrate and the OLED functional layers. It mediates by blocking harmful outgassing substances from reaching the OLED while still allowing the overall layer structure to be manufactured through simple direct contact deposition processes.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10249845B2Optoelectronic component and method for producing an optoelectronic component

Publication Date: 2019.04.02 DOLYA HOLDCO 5 LTD

AI summary

An optoelectronic component, comprising an electrically conductive layer, an electrically insulating layer formed above a partial region of the electrically conductive layer, an electrically weakly conductive encapsulation layer formed outside the partial region on the electrically conductive layer and above the partial region on the electrically insulating layer, a first electrode formed above the partial region on the electrically weakly conductive encapsulation layer, an organic functional layer structure formed on the first electrode, and a second electrode formed above the partial region on the organic functional layer structure and where the second electrode is formed outside the partial region on the electrically weakly conductive encapsulation layer.