Evolution of OLED Lamination Technology With Development of Display Form Factors

Abstract

With rapid advancements in OLEDs, lamination processes for free-form displays have become increasingly critical. This review comprehensively analyzes the core property requirements for optically clear adhesives (OCAs) and resins (OCRs) across evolving display form factors. For rigid displays, we examine thin-film uniformity via OCR fluid dynamics, slit-coater simulations, machine learning-based surrogate models, and strain-rate-dependent viscoelastic constitutive models for double-layered OCAs. For bended displays, simulation-based optimization of silicone pad and hydraulic systems is introduced to eliminate bubble defects. For rollable structures, we review non-linear finite element method (FEM) mechanisms incorporating hyperelastic and viscoelastic OCA properties, alongside UV-blocking visible-light curing systems. Finally, we discuss securing thickness uniformity through printhead temperature control and ensuring solvent orthogonality with the thin-film encapsulation (TFE) layer in inkjet-printed OCR processes for ultra-thin architectures. By addressing current challenges and outlining future research directions, this review offers comprehensive insights into display module engineering.