SiNxOy Gas Barrier Sheet for Organic EL Displays
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Solution Overview
Problem
Current gas barrier sheets for organic EL displays face challenges in achieving high productivity, maintaining gas barrier properties, and preventing curling, especially during heat cycle tests, while also ensuring adhesion and transparency.
Innovation Solution
A gas barrier sheet comprising a base material coated with a SiNxOy or SiNmOlCn film, optimized with specific absorption intensity and refractive index ranges, which enhances density and adhesion, reduces film stress, and maintains gas barrier properties even after heat cycle tests.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a UV cured resin layer is formed on a flexible base material followed by stacking of an inorganic barrier layer, then gas barrier properties are improved and curling is suppressed, but productivity is reduced due to multiple layer formation steps
Solution Approach 1:
The patent merges the base material and barrier layer into a single integrated gas barrier sheet structure, eliminating the need for separate UV cured resin layer formation and inorganic barrier layer stacking steps. The gas barrier sheet comprises a base material and an inorganic barrier layer formed directly thereon, combining multiple functions into one component.
Solution Approach 2:
The patent extracts and eliminates the intermediate UV cured resin layer from the multi-layer structure. By forming the inorganic barrier layer directly on the flexible base material, the unnecessary intermediate layer is removed, simplifying the structure and improving productivity while maintaining gas barrier performance.
2Ease of operation
If the inorganic barrier layer is made thinner to improve flexibility, then ease of operation is improved, but gas barrier properties deteriorate
Solution Approach 1:
The patent optimizes the thickness parameter of the inorganic barrier layer within the range of 1 nm to 100 nm, and controls the composition parameters (SiOx, AlOx, SiOxNy, SiNx, etc.) to achieve the desired balance between flexibility and gas barrier properties. By precisely controlling these parameters, the sheet maintains both flexibility and effective gas barrier performance.
3Stability of the object's composition
If a thicker acrylic resin layer is used to suppress curling, then stability is improved, but productivity is reduced and the structure becomes more complex
Solution Approach 1:
The patent combines the curling suppression function directly into the gas barrier sheet structure itself, rather than requiring a separate thicker acrylic resin layer. The integrated structure of base material and inorganic barrier layer inherently provides curling suppression, eliminating the need for additional complexity.
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 gas barrier sheet with high productivity, excellent gas barrier properties, suppressed curling, and improved adhesion, ensuring the integrity and performance of organic EL displays under various conditions.
Implementation Method 1
has an absorption intensity of IR absorption (830 cm−1 to 840 cm−1), corresponding to an Si—N bond, per unit thickness of 0.5×10−3/nm to 1.8×10−3/nm
Implementation Method 2
has a refractive index of 1.7 to 2.1
Data Source
AI summary
There is provided a gas barrier sheet that has high productivity, good gas barrier properties, and anticurling properties. In particular, a gas barrier sheet is provided that, even after a heat cycle test which is performed as a durability test for organic EL displays and the like, can suppress the occurrence of curling and can maintain gas barrier properties. The gas barrier sheet comprises a gas barrier film 3 provided on a base material 2. The gas barrier film 3 is an SiNxOy film, wherein x=0.5 to 1.5 and y=0.25 to 1, has an absorption intensity of IR absorption (830 cm−1 to 840 cm−1), corresponding to an Si—N bond, per unit thickness of 0.5×10−3/nm to 1.8×10−3/nm and has a refractive index of 1.7 to 2.1.