Trapezoidal Groove Buffer Structure for Flexible OLED Encapsulation
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Solution Overview
Problem
Current OLED panel structures face challenges in bending stress reduction and water/oxygen resistance, as the stacked encapsulation layers increase water and oxygen permeability, limiting the number of bendable screens and reducing their service life.
Innovation Solution
A buffer structure is created by forming trapezoidal grooves on an inorganic layer, where capillary channels are formed by depositing a second inorganic layer, allowing liquid organics to fill and cure within these channels, reducing bending stress without compromising water and oxygen insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stacked encapsulation layers are used to reduce bending stress, then bending properties are improved, but water and oxygen resistance deteriorates
Solution Approach 1:
The encapsulation structure is segmented into multiple inorganic layers with organic layers positioned only at specific locations (grooves) rather than forming continuous stacked layers. This segmentation allows stress distribution while preventing continuous water/oxygen pathways, resolving the contradiction between bending resistance and barrier performance.
Solution Approach 2:
The organic layer is placed locally only in the grooves between inorganic layers rather than uniformly across all interfaces. This local quality approach provides stress relief exactly where needed while maintaining water and oxygen barrier properties in the bulk inorganic layers, thus resolving the contradiction.
2Strength
If continuous organic layers are used in encapsulation, then bending stress is reduced, but water and oxygen insulation ability deteriorates
Solution Approach 1:
The organic material is extracted from continuous layer form and placed only in localized grooves. This extraction eliminates the continuous water/oxygen channel problem while retaining the stress relief function where the grooves are strategically positioned between inorganic layers.
Solution Approach 2:
The groove structures create controlled porous spaces that are filled with organic material. These porous regions provide stress relief and flexibility while the surrounding dense inorganic layers maintain water and oxygen barrier properties, resolving the contradiction between mechanical flexibility and barrier performance.
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 approach effectively increases the number of bendable display panels while maintaining the inorganic layers' insulating properties, enhancing the durability and lifespan of flexible OLED screens.
Implementation Method 1
forming capillary channels; making liquid organics enter the capillary channels
Implementation Method 2
liquid organics enter the capillary channels and cured to form an organic layer
Data Source
AI summary
The present disclosure provides a buffer structure, a display panel, and a manufacturing method of the buffer structure. The display panel comprises at least one of the buffer structures. The buffer structure comprises a first inorganic layer, a second inorganic layer, and an organic layer. Trapezoidal grooves are disposed at intervals on one side surface of the first inorganic layer; the second inorganic layer is disposed on one side surface having the trapezoidal grooves of the first inorganic layer, covers inside surfaces of the trapezoidal grooves, is connected at openings of the trapezoidal grooves, and forms capillary channels; and the organic layer is filled inside the capillary channels.