Inorganic Electroluminescence Device Metal Mesh Electrode

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Solution Overview

Problem

Conventional inorganic electroluminescence devices face issues with thermal, chemical, and physical durability, particularly when exposed to high temperatures and humidity, and are expensive, making them unsuitable for automotive applications that require high durability and resistance to heat shock.

Innovation Solution

The use of a transparent electrode layer comprising a metal mesh or metal-patterned substrate, such as stainless steel or aluminum, with a polymer material and a light diffusing agent, which is applied to a glass sheet or base substrate, and stacked with dielectric and fluorescent powder layers to enhance heat resistance, moisture resistance, and manufacturing cost-effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional ITO transparent electrodes are used, then the device can be manufactured with standard materials, but the thermal, chemical, and physical durability are poor and the cost is high

Engineering Contradiction:

Improvethermal, chemical, and physical durabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive ITO electrodes with inexpensive metal mesh or metal-patterned substrates that can be easily manufactured. These alternative electrode materials significantly reduce manufacturing costs while providing superior durability, effectively applying the principle of using cheap substitutes for expensive materials.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent employs composite structures combining metal meshes or metal patterns with polymer materials and dielectric layers. This composite approach creates electrodes that leverage the advantages of each material: the metal provides durability and conductivity, while the polymer and dielectric layers provide insulation and functional properties, achieving both cost reduction and performance improvement.

Inventive Principle:

Principle #40Composite materials

2Reliability

If ITO/PET electrodes are used, then the device can be manufactured with conventional materials, but the electrical properties are drastically degraded due to low-temperature and high-temperature heat shock

Engineering Contradiction:

Improveheat shock resistanceVSAvoidtemperature degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameters of the electrode by replacing ITO/PET with metal mesh or metal-patterned substrates. These material parameter changes fundamentally alter the thermal stability, allowing the electrode to withstand extreme temperature cycles from -40°C to 80°C without degrading electrical properties, thus resolving the heat shock resistance issue.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The metal mesh or metal-patterned substrates used in the patent are inherently more resistant to thermal shock than conventional ITO/PET electrodes. These alternative materials maintain their structural and electrical integrity across wide temperature ranges, providing the heat shock resistance needed for automotive applications.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If nano-scale transparent electrode materials are used, then the transparent electrode function is achieved, but the thermal, chemical and physical durability are very poor and the cost is expensive

Engineering Contradiction:

Improvethermal and chemical durabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive nano-scale transparent electrode materials with inexpensive metal mesh or metal-patterned substrates. These macro-scale metal structures are significantly more durable thermally and chemically while being much cheaper to manufacture, directly addressing the contradiction between durability and cost.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent uses composite structures combining metal meshes or patterns with polymer binders and dielectric layers. This composite approach achieves both the required electrical transparency and superior thermal/chemical durability, while the simplicity of the structure keeps manufacturing costs low compared to complex nano-materials.

Inventive Principle:

Principle #40Composite materials

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 improves the heat resistance, moisture resistance, and heat shock resistance of inorganic electroluminescence devices, maintaining light uniformity and luminance while reducing manufacturing costs, making them suitable for automotive applications like vehicle sunroofs.

Implementation Method 1

a polymer material and a light diffusing agent, which is applied to a glass sheet or base substrate

Methodology Applied

Scientific EffectLight diffusion: Scattering

Data Source

PatentUS11259371B2Inorganic electroluminescence device and method for manufacturing the same

Publication Date: 2022.02.22 HYUNDAI MOTOR CO LTD

AI summary

An inorganic electroluminescence device having heat resistance, moisture resistance and physical durability improved by applying a transparent electrode layer including a metal mesh substrate or a metal patterned substrate, and a method for manufacturing the same.