Multi-Layered Protective Layer for Organic EL Sealing
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Solution Overview
Problem
The existing organic electroluminescence (EL) devices face issues with sealing performance due to defects in the protective film, particularly when there are steps on the surface of the organic EL element, leading to deterioration in the quality and reliability of the device.
Innovation Solution
The organic electroluminescence device incorporates a protective layer with a specific configuration of insulating films, including a first insulating film formed by chemical vapor deposition, a second insulating film by atomic layer deposition, and additional films to enhance sealing performance, using inorganic materials with varying densities to mitigate surface unevenness and defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective film is formed to prevent moisture entry, then sealing performance is improved, but defects occur when there are steps on the surface
Solution Approach 1:
The protective film is divided into multiple insulating films (first, second, third, fourth insulating films) with different densities and functions. The first and third insulating films have lower density to fill steps, while the second and fourth insulating films have higher density to provide barrier function, segmenting the protective function across multiple layers
Solution Approach 2:
Different regions of the protective film structure have different densities tailored to local requirements: lower density in films contacting the stepped surface to ensure coverage, and higher density in intermediate films to provide moisture barrier, creating local quality variations that solve both problems
2Ease of manufacture
If the protective film structure is simplified, then manufacturing is easier, but sealing performance deteriorates
Solution Approach 1:
The protective film uses a composite structure of four insulating films with different densities formed by different methods (CVD and ALD). This composite approach combines the advantages of each material type to achieve both good sealing performance and manufacturability
Solution Approach 2:
The insulating films are arranged in a nested multi-layer structure where each film is deposited on top of the previous one, creating a nested configuration that maximizes sealing effectiveness within a compact structure
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 configuration effectively enhances the sealing performance of the protective layer, reducing moisture transmission and improving the reliability and longevity of the organic EL device by preventing defect progression and maintaining optical transparency.
Implementation Method 1
each of the first insulating film, the third insulating film, and the fifth insulating film is formed by a CVD method using plasma
Implementation Method 2
a CVD method using plasma
Implementation Method 3
each of the second insulating film, and the fourth insulating film is formed by an ALD method using plasma
Implementation Method 4
an ALD method using plasma
Data Source
AI summary
An organic electroluminescence device includes an organic electroluminescence element, and a protective layer configured to protect the organic electroluminescence element, wherein the protective layer includes a first insulating film, a second insulating film, a third insulating film, a fourth insulating film, and a fifth insulating film, each of the first insulating film, the second insulating film, the third insulating film, the fourth insulating film, and the fifth insulating film is formed of an inorganic material, and a density of the first insulating film is lower than a density of each of the third insulating film and the fifth insulating film.