Quantum Dot LED Inorganic Encapsulation for Water Isolation
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Solution Overview
Problem
Quantum dot LEDs face significant efficiency and lifespan reductions due to temperature quenching and exposure to water and oxygen, necessitating improved isolation and heat dissipation measures.
Innovation Solution
A quantum dot LED structure featuring a pair of electrodes, an LED chip, a quantum dot layer, a glue layer, and an inorganic encapsulation layer formed using atomic layer deposition, which provides a water and oxygen isolation environment, along with an optional organic protection layer to enhance durability and light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If quantum dots are exposed in water and oxygen environment, then the device structure is simple, but the luminous efficiency decreases quickly
Solution Approach 1:
The patent applies inert atmosphere by filling the encapsulation cavity with nitrogen or other inert gases to displace water and oxygen, creating a protective environment that prevents oxidation and maintains quantum dot luminous efficiency without complicating the device structure
Solution Approach 2:
The patent uses composite encapsulation structures combining organic encapsulation layers (such as epoxy resin or UV curing resin) with inorganic encapsulation layers (such as silicon oxide or silicon nitride), creating a multi-layer protective barrier that effectively blocks water and oxygen while maintaining manufacturing feasibility
2Productivity
If the temperature is increased, then the processing capability is improved, but the luminous efficiency decreases due to temperature quenching
Solution Approach 1:
The patent divides the encapsulation structure into multiple functional layers (organic encapsulation layer and inorganic encapsulation layer) with different thermal and protective properties, allowing each layer to address specific requirements while collectively managing temperature effects and maintaining luminous efficiency
Solution Approach 2:
The patent optimizes the thickness parameters of encapsulation layers (controlling organic layer thickness at 1-10 μm and inorganic layer thickness at 50-200 nm) to balance thermal management and protective functions, ensuring that heat can be dissipated while maintaining effective isolation from environmental factors
3Reliability
If a thick encapsulation layer is used to block water and oxygen, then the isolation ability is improved, but the optical performance deteriorates due to increased optical density
Solution Approach 1:
The patent applies different material properties to different layers: the organic encapsulation layer provides bulk protection with higher thickness (1-10 μm) for water and oxygen blocking, while the inorganic encapsulation layer provides a thin dense barrier (50-200 nm) with excellent optical transparency, achieving both isolation and optical performance through localized material optimization
Solution Approach 2:
The patent combines organic and inorganic encapsulation materials with complementary properties, where the organic layer provides mechanical protection and bulk sealing, while the inorganic layer provides a dense molecular barrier and optical clarity, creating a synergistic composite structure that achieves high isolation ability with minimal optical density increase
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 increases the luminous efficiency and lifespan of quantum dots, enabling a high color gamut and improved LCD performance, including BT2020>90% color gamut and reduced optical density in direct backlight modules.
Implementation Method 1
an inorganic encapsulation layer that packages and covers the pair of electrodes, the LED chip, the quantum dot layer and the glue layer
Implementation Method 2
the inorganic encapsulation layer is manufactured by an atomic layer deposition method
Implementation Method 3
a quantum dot layer disposed on the LED chip
Implementation Method 4
A Quantum Dot (QD) is a semiconductor nanostructure that chains conduction band electron, valence band hole and exciton in three spaces... can emit florescent light after being excited
Data Source
AI summary
A quantum dot LED and a manufacturing method for the same are disclosed. The quantum dot LED includes a pair of electrodes disposed separately and side by side; an LED chip disposed on the pair of electrodes and electrically connected to the pair of electrodes; a quantum dot layer disposed on the LED chip; a glue layer disposed on the quantum dot layer; and an inorganic encapsulation layer that packages and covers the pair of electrodes, the LED chip, the quantum dot layer and the glue layer. The present invention can provide a water and oxygen isolation environment, which is beneficial to increase the luminous efficiency and life of the quantum dots. Adopting an atomic layer deposition method to form the inorganic encapsulation layer, the surface is smooth and even in thickness, the problem of cracking of the film layer will not generate.