Roll Lamination Encapsulation Laminate for OLED Manufacturing
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Solution Overview
Problem
The manufacturing process of organic light emitting apparatuses is complex and costly, requiring improvements in process efficiency and cost reduction to enhance productivity.
Innovation Solution
A laminate for encapsulation is manufactured using a roll lamination method, involving an encapsulation film, an adhesive film, and a protective film, which simplifies the process and allows for the simultaneous cohesion of multiple organic light emitting units, reducing the need for vacuum conditions and enabling flexible handling of the laminate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing processes are used for organic light emitting apparatuses, then manufacturing precision and reliability are maintained, but process complexity and costs increase significantly
Solution Approach 1:
The patent combines multiple encapsulation layers (first encapsulation layer, second encapsulation layer) and adhesive layers into a single integrated laminate structure. This merging of previously separate manufacturing steps into one unified laminate reduces process complexity while maintaining the protective and adhesive functions needed for organic light emitting apparatuses.
Solution Approach 2:
The laminate is prepared in advance with pre-formed encapsulation layers and adhesive layers in a factory setting. This preliminary action allows the complex multi-layer structure to be manufactured under controlled conditions beforehand, simplifying the final assembly process at the manufacturing site and reducing overall process complexity.
2Productivity
If conventional encapsulation methods are used, then encapsulation reliability is ensured, but productivity and manufacturing efficiency decrease
Solution Approach 1:
Multiple encapsulation functions are merged into a single laminate product that can be applied in one step. The laminate integrates the first encapsulation layer, adhesive layer, and second encapsulation layer, allowing simultaneous fulfillment of protection and bonding requirements, thereby improving productivity without compromising reliability.
Solution Approach 2:
The patent specifies controlled parameter ranges for the laminate including thickness (1-100 μm for first encapsulation layer, 1-50 μm for second encapsulation layer) and adhesive strength (0.1-10 N/10mm). By optimizing these parameters, the laminate achieves both high productivity through simplified application and reliable encapsulation performance.
3Manufacturing precision
If complex vacuum handling systems are used, then manufacturing precision is maintained, but process costs and equipment complexity increase
Solution Approach 1:
The laminate structure creates a uniform bonding interface between encapsulation layers and the organic light emitting apparatus. The adhesive layer provides consistent adhesive strength across the bonding surface, eliminating the need for complex vacuum handling systems to maintain alignment precision during assembly.
Solution Approach 2:
The adhesive layer acts as an intermediary between the encapsulation layers and the organic light emitting apparatus. This intermediary provides reliable bonding without requiring complex vacuum or clamping systems, simplifying the equipment needed while maintaining manufacturing precision through controlled adhesive properties.
Data Source
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AI summary
The present application relates to a laminate for encapsulation, an organic light emitting apparatus, and methods for manufacturing the same, and process costs may be reduced and productivity may be significantly enhanced by manufacturing the organic light emitting apparatus using the laminate for encapsulation through a roll process.