Silane-Coated Metal Film Adhesion for OLED Encapsulation
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Solution Overview
Problem
The metal encapsulation process in OLED display production faces issues with peeling badness, leading to adhesive and metal film waste, production delays, and increased costs due to the strong adhesion between the protective film and adhesive layer, which results in incomplete encapsulation.
Innovation Solution
A method involving the formation of a silane film on the metal film with active groups that react with the adhesive layer, enhancing adhesion and preventing the adhesive layer from being taken away during peeling, while also using an iron-nickel alloy for the metal film to match thermal expansion coefficients and a hydrophobic group for improved moisture barrier properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective film is applied to the adhesive layer, then the adhesive layer is protected during handling and storage, but the protective film adheres too strongly to the adhesive layer causing peeling badness during encapsulation
Solution Approach 1:
A release film is introduced as an intermediary layer between the protective film and the adhesive layer. This release film has controlled adhesion properties that allow the protective film to be easily separated from the adhesive layer during encapsulation, preventing peeling badness while maintaining protection during handling and storage.
Solution Approach 2:
The adhesion parameters of the protective film are modified by selecting materials with appropriate surface energy characteristics. The protective film is chosen to have lower adhesion to the adhesive layer compared to its protection function, allowing easy separation during encapsulation while providing sufficient protection during handling.
2Reliability
If the adhesive layer is strongly adhered to the protective film, then the adhesive layer is well-protected during handling, but the adhesive layer is taken away during peeling causing material waste and production delays
Solution Approach 1:
The release film serves as a mediator that decouples the adhesion strength between the protective film and adhesive layer. It provides sufficient protection during handling while enabling clean separation during encapsulation, preventing adhesive layer detachment and eliminating rework.
Solution Approach 2:
The protective film system is segmented into multiple functional layers: the protective film for external protection, the release film for controlled separation, and the adhesive layer for bonding. This segmentation allows each layer to perform its specific function optimally without interfering with others.
3Device complexity
If the metal film is directly bonded to the adhesive layer, then the encapsulation structure is simple, but the adhesion between metal film and adhesive layer is insufficient leading to peeling issues
Solution Approach 1:
The encapsulation structure uses a composite material system consisting of metal film, adhesive layer, release film, and protective film. Each material is selected for its specific properties, and their combination creates synergistic effects that provide both strong adhesion and easy separation where needed.
Solution Approach 2:
The release film acts as an intermediary between the metal film-adhesive layer bond and the protective film. It allows the metal film and adhesive layer to be strongly bonded for encapsulation integrity while enabling the protective film to be easily removed without affecting the bond strength.
4Productivity
If the adhesive layer is exposed without a protective film, then encapsulation process is simpler, but the adhesive layer is damaged during handling and storage
Solution Approach 1:
The protective film is applied in advance to the adhesive layer before the encapsulation process. This preliminary protection prevents damage during handling, storage, and transportation, ensuring the adhesive layer remains intact and ready for encapsulation without requiring additional protective measures during the process.
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 solution improves the adhesion between the metal film and adhesive layer, reduces peeling issues, increases production yield, and enhances the moisture barrier properties, thereby reducing production costs and improving the encapsulation quality.
Implementation Method 1
forming a silane film on the first surface of the metal film, wherein a surface of the silane film away from the metal film has an active group; and attaching the first surface formed with the silane film to an adhesive layer, so as to react and bond the active group and the adhesive layer
Implementation Method 2
the surface of the silane film away from the metal film further comprises a hydrophobic group
Data Source
AI summary
There is provided a metal encapsulation structure and a production method thereof, an encapsulation method for a display panel, and a display device. This production method comprises steps of: providing a metal film having a first surface and a second surface opposite to the first surface; forming a silane film on the first surface of the metal film, wherein a surface of the silane film away from the metal film has an active group; and attaching the first surface formed with the silane film to an adhesive layer, so as to react and bond the active group and the adhesive layer.