Flexible OLED Lighting with Composite Substrate Design
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Solution Overview
Problem
Existing OLED technologies face challenges in creating flexible lighting devices that can deform mechanically without shear deformation under external forces, such as wind, while maintaining structural integrity and efficiency.
Innovation Solution
The development of flexible OLED devices with substrates that have specific mechanical properties, including a flexural rigidity between 10−1 Nm and 10−6 Nm, and a critical strain energy release rate to material density ratio greater than 0.05 J m/Kg, allowing for axial, bending, and torsional degrees of freedom without shear, and featuring a barrier layer and lamination layer for encapsulation and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the substrate is made flexible to enable mechanical deformation, then adaptability is improved, but structural integrity deteriorates
Solution Approach 1:
The device uses a composite structure consisting of a flexible substrate combined with rigid support elements (frames or ribs) to achieve both flexibility and structural integrity. The composite design allows the substrate to deform mechanically while the support elements maintain overall structural strength and prevent failure under stress.
2Strength
If the device is made rigid to maintain structural integrity, then strength is improved, but adaptability deteriorates
Solution Approach 1:
The device structure is segmented into flexible substrate regions and rigid support regions. The support elements are strategically positioned to provide structural reinforcement only where needed, allowing other areas to remain flexible and deformable. This segmentation enables the device to maintain overall integrity while achieving local adaptability.
3Ease of operation
If the substrate is made thin to improve flexibility, then ease of operation is improved, but reliability deteriorates
Solution Approach 1:
The device employs thin-film encapsulation layers and flexible protective coatings that conform to the thin substrate while providing environmental protection and preventing delamination. These thin protective films maintain the substrate's flexibility while enhancing its reliability by protecting against moisture, oxygen, and mechanical damage.
4Reliability
If the device is made thick to improve reliability, then durability is improved, but ease of operation deteriorates
Solution Approach 1:
Instead of increasing thickness in the vertical dimension to improve durability, the device uses a two-dimensional network of support elements and reinforcement structures distributed across the substrate plane. This dimensional approach provides structural strength and protection without compromising the substrate's flexibility and thin-profile characteristics.
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
These devices can deform non-linearly under applied loads, exhibit controlled mechanical reactions like fluttering or flag-like motion, and maintain performance and durability by preventing delamination and stress distribution across the substrate.
Implementation Method 1
OLEDs make use of thin organic films that emit light when voltage is applied across the device
Implementation Method 2
One application for phosphorescent emissive molecules is a full color display
Data Source
AI summary
A first device and methods for manufacturing the first device are provided. The first device may comprise a flexible substrate and at least one organic light emitting device (OLED) disposed over the flexible substrate. The first device may have a flexural rigidity between 10−1 Nm and 10−6 Nm, and the ratio of the critical strain energy release rate to the material density factor for the first device may be greater than 0.05 J m/Kg.