Flexible OLED Module with Nested Cover Element
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Solution Overview
Problem
Existing optoelectronic modules are not space-efficient and lack effective protection against environmental and mechanical influences, particularly in outdoor or vehicle lighting applications.
Innovation Solution
A space-saving optoelectronic module design featuring a mechanically flexible organic light source housed within a rigid and protective structure, with a cover element that allows light transmission while providing protection against environmental and UV radiation, using a combination of materials like metal, carbon-fiber-reinforced plastic, and a transparent or radiation-opaque cover element, and an anisotropic conductive adhesive for secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional optoelectronic module design is used, then the housing and protective structures take up significant space, but this results in reduced space efficiency and increased module size
Solution Approach 1:
The organic light source is nested within the housing structure, with the illuminating surface positioned in the opening. The cover element is then applied directly to the illuminating surface, creating a nested configuration where each component is integrated within the previous one, minimizing overall module volume while maintaining protection.
Solution Approach 2:
A thin cover element is used to protect the organic light source from environmental influences. This thin film approach provides necessary protection against moisture and contaminants while occupying minimal space, replacing bulkier conventional protective structures.
2Volume of moving object
If the organic light source is positioned closer to the housing opening to save space, then space efficiency improves, but mechanical protection and secure mounting become more difficult
Solution Approach 1:
The cover element serves multiple functions simultaneously: it protects the organic light source from environmental influences, provides mechanical support, and secures the light source in position within the opening. This merging of functions eliminates the need for separate protective structures, achieving compact dimensions while maintaining mechanical strength.
Solution Approach 2:
The cover element is designed as a multi-functional component that combines protective, structural, and mounting functions. By making the cover element universal in its functions, the design achieves space efficiency without compromising mechanical protection or secure mounting of the organic light source.
3Illumination intensity
If a transparent cover element is used to maximize light transmission, then light output efficiency improves, but protection against UV radiation and environmental damage decreases
Solution Approach 1:
The cover element has different optical properties in different regions or for different wavelengths. It is designed to be transparent to visible light wavelengths to maximize light transmission, while simultaneously being opaque or absorptive to UV radiation wavelengths, providing selective protection where needed while maintaining visibility.
Solution Approach 2:
The cover element is made from a composite material or a material with composite properties that combines high visible light transmission with UV radiation blocking. This allows the single cover element to simultaneously achieve both light output efficiency and protection against harmful UV radiation.
4Strength
If rigid housing materials are used to provide mechanical protection, then strength and durability improve, but the overall module complexity and manufacturing difficulty increase
Solution Approach 1:
The housing is made from a composite material such as carbon-fiber-reinforced plastic that provides high mechanical strength and durability comparable to metal, while being easier to manufacture and process. This composite material approach maintains mechanical protection while reducing manufacturing complexity.
Solution Approach 2:
The housing design uses thin-walled structures that provide sufficient mechanical protection through optimized geometry and material selection, reducing the amount of material needed and simplifying manufacturing processes while maintaining adequate strength and durability for the application.
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 enables a compact, durable, and efficient lighting solution that protects the organic light source from mechanical and environmental damage while maintaining high light transmission, suitable for various lighting applications including motor vehicle exterior lighting.
Implementation Method 1
The organic light source can comprise an organic layer stack having an active layer, a cathode and an anode for electrical contacting purposes and a thin film encapsulation. In particular, the organic light source emits visible light during operation.
Implementation Method 2
an anisotropic conductive adhesive for secure electrical connections
Data Source
AI summary
The invention relates to an optoelectronic module, comprising a housing (11) having a first housing part (11) having a first cover surface (11a) and an opening (4); a mechanically flexibly designed organic light source (2) having an illuminating surface (2a); and a cover element (3) which is mounted on the illuminating surface (2a) and has a light-transmissive surface (3a) facing away from the illuminating surface (2a), wherein the organic light source (2) is introduced at least at some points into the opening (14), the first cover surface (11a) is curved and/or bowed, the size of the illuminating surface (2a) is at least 1 cm2, preferably at least 5 cm2, and the distance between the illuminating surface (2a) and the first cover surface (11a) is at most 1 cm, preferably at most 5 mm.