Flexible EL Module Structure for Moisture Barrier and Charge Control
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Solution Overview
Problem
Flexible light-emitting devices have short lifetimes due to the use of plastic substrates with low heat resistance, leading to poor moisture protection and increased electrical charging, which results in malfunctions such as static electricity-induced failures.
Innovation Solution
A flexible light-emitting device is manufactured with a high-heat-resistant substrate like glass for forming a protective film, which is then transferred to a plastic substrate with a metal substrate adhered using an adhesive, incorporating a nitrogen and silicon insulating film and a metal substrate with a thickness of 10 μm to 200 μm for enhanced moisture protection and electrical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a plastic substrate is used to provide flexibility, then the device can be bent and is lightweight, but the substrate has high permeability to moisture and low heat resistance leading to short lifetime
Solution Approach 1:
The patent uses a composite structure consisting of a plastic substrate combined with a glass substrate. The plastic substrate provides flexibility and light weight, while the glass substrate provides low moisture permeability and high heat resistance. This composite approach allows the device to simultaneously achieve flexibility and long lifetime without compromising either property.
2Reliability
If a glass substrate is used to provide high heat resistance and low moisture permeability, then a protective film can be formed with high quality, but the device loses flexibility and becomes heavy
Solution Approach 1:
The patent combines glass and plastic substrates in a composite structure. The glass substrate serves as the base for forming high-quality protective films with excellent moisture barrier properties, while the plastic substrate layer provides the necessary flexibility and reduces overall weight. This division of functions resolves the contradiction between protective film quality and flexibility.
Solution Approach 2:
The substrate system is segmented into distinct functional layers: a glass substrate portion dedicated to providing thermal stability and moisture protection, and a plastic substrate portion dedicated to providing flexibility and light weight. This segmentation allows each material to optimize its specific function without compromise.
3Reliability
If a metal thin film is used to prevent moisture entry, then low permeability is achieved, but visible light transmission is blocked with normal thickness
Solution Approach 1:
The patent employs an extremely thin metal film (5 nm to 50 nm) as a moisture barrier layer. At this ultra-thin scale, the metal film provides effective moisture protection while remaining transparent to visible light. This thin film approach allows simultaneous achievement of low permeability and high light transmission that would be impossible with conventional thicknesses.
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 extends the lifetime of flexible light-emitting devices, reduces electrical charging, and simplifies the manufacturing process while maintaining flexibility and visibility, making the devices more durable and cost-effective.
Implementation Method 1
a nitrogen and silicon insulating film provided over a plastic substrate
Implementation Method 2
a metal substrate adhered using an adhesive
Data Source
AI summary
It is an object to provide a flexible light-emitting device with long lifetime in a simple way and to provide an inexpensive electronic device with long lifetime using the flexible light-emitting device. A flexible light-emitting device is provided, which includes a substrate having flexibility and a light-transmitting property with respect to visible light; a first adhesive layer over the substrate; an insulating film containing nitrogen and silicon over the first adhesive layer; a light-emitting element including a first electrode, a second electrode facing the first electrode, and an EL layer between the first electrode and the second electrode; a second adhesive layer over the second electrode; and a metal substrate over the second adhesive layer, wherein the thickness of the metal substrate is 10 μm to 200 μm inclusive. Further, an electronic device using the flexible light-emitting device is provided.