Flexible Light Emitting Device with Embedded Insulating Convex Portion
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Solution Overview
Problem
Existing light emitting devices face challenges in achieving a thinner form factor and high yield manufacturing while maintaining reliability and preventing defects in shape or characteristics, particularly when integrating light emitting elements with flexible substrates and resin films.
Innovation Solution
A light emitting device design that includes a flexible substrate, a light emitting element with a first electrode, an insulating layer with a convex portion, an electroluminescent layer, and a second electrode, all covered by a resin film, where the convex portion of the insulating layer is embedded within the resin film, enhancing the fixing strength and preventing peeling during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a light emitting element is integrated with flexible substrates and resin films to achieve a thinner form factor, then device thickness is reduced and flexibility is improved, but manufacturing yield decreases due to peeling defects and shape defects
Solution Approach 1:
The convex portion is formed on the insulating layer before assembling the light emitting device, creating a pre-positioned anchoring structure that prevents peeling during subsequent manufacturing processes. This preliminary structural preparation ensures proper embedding in the resin film without causing defects
Solution Approach 2:
The convex portion of the insulating layer acts as an intermediary anchoring structure between the rigid light emitting element and the flexible resin film, providing mechanical interlocking that prevents peeling while maintaining flexibility and thin profile
2Adaptability or versatility
If the device is thinned and made flexible by using flexible substrates, then adaptability to curved surfaces is improved, but structural stability deteriorates leading to peeling during manufacturing
Solution Approach 1:
The convex portion of the insulating layer is embedded within the resin film, creating a nested structure where the rigid element is anchored within the flexible matrix. This nested configuration provides structural stability while maintaining overall flexibility for curved surface adaptation
3Ease of manufacture
If conventional light emitting device structures are used without convex portions, then manufacturing process is simpler, but peeling occurs during manufacturing reducing reliability
Solution Approach 1:
The convex portion is formed on the insulating layer during the insulating layer formation process itself, without requiring separate complex assembly steps. This preliminary formation integrates seamlessly into existing manufacturing workflows while dramatically improving reliability by preventing peeling defects
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 design allows for the creation of a highly reliable, thin, and flexible light emitting device with improved yield, enabling the device to be bonded to various base materials, including those with curved surfaces, and reducing weight and manufacturing defects.
Implementation Method 1
a light emitting element utilizing electroluminescence (EL), and this light emitting element includes a light emitting material interposed between a pair of electrodes and can provide light emission from the light emitting material by voltage application
Data Source
AI summary
Thinned and highly reliable light emitting elements are provided. Further, light emitting devices in which light emitting elements are formed over flexible substrates are manufactured with high yield. One light emitting device includes a flexible substrate, a light emitting element faulted over the flexible substrate, and a resin film covering the light emitting element, and in the light emitting element, an insulating layer serving as a partition has a convex portion and the convex portion is embedded in the resin film, that is, the resin film covers an entire surface of the insulating layer and an entire surface of the second electrode, whereby the light emitting element can be thinned and highly reliable. In addition, a light emitting device can be manufactured with high yield in a manufacturing process thereof.