Sealing Sheet Microstructure for Gas Barrier

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Solution Overview

Problem

Existing sealing technologies for organic EL elements fail to adequately prevent water vapor entry, leading to deterioration in emission properties over time.

Innovation Solution

A sealing sheet with a base resin layer and a sealing resin layer, where the base resin layer has a microstructure with protrusions of 1 to 50 μm in height arranged two-dimensionally, and the sealing resin layer is applied on top, providing a gas barrier capability by suppressing water vapor entry both vertically and horizontally.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a flexible film sealing method is used for organic EL elements, then the sealing process becomes simpler and more flexible, but the gas barrier capability is insufficient and water vapor entry cannot be adequately prevented

Engineering Contradiction:

Improvesealing process simplicityVSAvoidgas barrier capability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The sealing sheet combines a base resin layer (polyester or polypropylene) with a sealing resin layer (rubber-based resin containing polyisobutylene), creating a composite structure that integrates the dimensional stability of the base layer with the excellent gas barrier properties of the sealing layer, thereby achieving both ease of manufacture and superior gas barrier capability

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The sealing resin layer is applied selectively to specific regions of the base resin layer, particularly at edges and corners where water vapor penetration is most likely to occur, providing enhanced local gas barrier protection without compromising overall sealing simplicity

Inventive Principle:

Principle #3Local quality

2Device complexity

If conventional sealing methods are used, then the sealing structure remains simple, but water vapor entry occurs vertically and horizontally leading to element deterioration

Engineering Contradiction:

Improvesealing structure simplicityVSAvoidwater vapor entry

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The sealing resin layer extends not only vertically to seal the top surface but also horizontally along the edges and corners of the base resin layer, creating a three-dimensional sealing configuration that blocks water vapor entry from both vertical and horizontal directions while maintaining structural simplicity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The sealing resin layer is embedded within and integrated to the base resin layer, with the sealing layer nested on top of the base layer, forming a multi-layer nested structure that provides comprehensive water vapor barrier protection without significantly increasing overall device complexity

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS10326106B2Sealing sheet, member for electronic devices, and electronic device

Publication Date: 2019.06.18 LINTEC CORP

AI summary

The present invention is a sealing sheet comprising at least a base resin layer and a sealing resin layer, the base resin layer having a microstructure that is provided to one surface of the base resin layer,the sealing resin layer being provided on a side of the base resin layer on which the microstructure is provided, andthe microstructure having a protrusion that has a maximum difference in height (H) of 1 to 50 μm and is arranged two-dimensionally on the surface of the base resin layer, andan electronic device member, andan electronic device.The sealing sheet according to the invention exhibits an excellent gas barrier capability that suppresses or reduces the entry of a gas (e.g., water vapor) not only in the vertical direction, but also in the horizontal direction (from the edge) with respect to the surface of the sealing sheet.