Photocurable Water Scavenging Layer for OLED Moisture Protection
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Solution Overview
Problem
Current methods for manufacturing water scavenging layers for opto-electric devices, such as OLEDs, face challenges in achieving stability, flowability, and cost-effectiveness, particularly in preventing moisture ingress through pinholes in the cathode layer, which leads to degradation and efficiency loss.
Innovation Solution
A photocurable resin composition containing metal oxide particles, such as CaO, BaO, or MgO, with specific properties like low water content and high hydrophobicity, is developed for easy dispensing and printing, featuring a curable matrix with a low viscosity and high hydrophobicity to form a stable, transparent, and effective water scavenging layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a water scavenging layer is applied to protect opto-electric devices from moisture ingress, then device reliability is improved, but manufacturing complexity increases due to the need for stable, flowable compositions with specific properties
Solution Approach 1:
The patent modifies the chemical and physical parameters of the composition by selecting specific (meth)acrylate monomers and oligomers with controlled functionality and hydrophobicity. By adjusting the ratio of monofunctional to multifunctional (meth)acrylates and controlling the water content to below 500 ppm, the composition achieves both stability during storage and proper flowability during application, thereby improving device protection while maintaining manufacturing simplicity.
Solution Approach 2:
The patent creates a composite photocurable composition combining hydrophobic (meth)acrylate monomers, oligomers, and metal oxide particles (such as CaO, BaO, or MgO) in a controlled matrix. This composite structure provides both the flowability needed for easy dispensing and the water scavenging capability for device protection, resolving the contradiction between reliability improvement and manufacturing complexity.
2Reliability
If the composition has high hydrophobicity and low water content to prevent moisture ingress, then water scavenging efficiency is improved, but ease of manufacture deteriorates due to handling difficulties
Solution Approach 1:
The patent carefully controls the water content parameter to be below 500 ppm (preferably below 200 ppm) while maintaining high hydrophobicity through the selection of specific (meth)acrylate compounds with ClogP values above 2. This parameter optimization ensures high water scavenging efficiency while the low viscosity (below 500 mPa·s) of the composition facilitates easy handling and processing during manufacturing.
3Ease of operation
If the composition is made flowable with low viscosity for easy dispensing and printing, then ease of operation is improved, but stability deteriorates due to potential phase separation or premature curing
Solution Approach 1:
The patent achieves the optimal balance between flowability and stability by controlling the viscosity to be below 500 mPa·s at 20°C through the selection of appropriate monofunctional (meth)acrylate diluents, while simultaneously maintaining composition stability by keeping water content below 500 ppm and using stabilizers. The low viscosity enables easy dispensing and printing, while the controlled water content and stabilizer system prevent phase separation and premature curing during storage and application.
4Reliability
If metal oxide particles are incorporated to enhance water scavenging properties, then water scavenging efficiency is improved, but manufacturing precision deteriorates due to particle distribution control
Solution Approach 1:
The patent incorporates metal oxide particles (CaO, BaO, or MgO) into the (meth)acrylate-based composition to create a composite material with enhanced water scavenging capability. The particles are dispersed in the low-viscosity matrix, which facilitates uniform distribution during application. The combination of the reactive metal oxide particles with the flowing (meth)acrylate matrix ensures both high water scavenging efficiency and acceptable manufacturing precision through easy mixing and application.
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 provides a stable, flowable, and cost-effective water scavenging layer with exceptional water scavenging properties and long-term protection for opto-electric devices, reducing moisture ingress and maintaining device efficiency.
Implementation Method 1
A first organic layer comprising a photocurable resin and metal oxide particles, such as CaO, BaO or MgO, in a distributed manner, is produced by curing the photocurable resin
Implementation Method 2
A photocurable resin composition containing metal oxide particles, such as CaO, BaO, or MgO, with specific properties like low water content and high hydrophobicity, is developed for easy dispensing and printing
Implementation Method 3
featuring a curable matrix with a low viscosity and high hydrophobicity to form a stable, transparent, and effective water scavenging layer
Data Source
Figure 1
AI summary
A radiation curable resin composition comprising: (A) metal oxide particles; (B) at least one photoinitiator, preferably a radical photoinitiator, or any mixture thereof; (C) at least one acrylate or methacrylate component with a Clog P higher than 2, preferably higher than 4, more preferably higher than 5,or any mixture thereof; (D) at least one monofunctional acrylate or methacrylate diluent component, preferably with a viscosity below 40 mPa?s at 20?C,or any mixture thereof; (E) at least one acrylate or methacrylate component with functionality equal or higher than 3, preferably 3 or 4,or any mixture thereof; can be advantageously used, for example,in multilayer barrier stack for the production of organic opto-electric or opto-electronic device, such as Organic Light Emitting Diode (OLED).