Lighting Module Multilayer Film Contact Structure
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Solution Overview
Problem
The challenge lies in reliably contacting and protecting surface lighting elements, such as OLEDs or QLEDs, which are sensitive to mechanical stress and prone to corrosion, while maintaining a homogeneous current density distribution, limiting their maximum size and making them difficult to connect effectively for larger luminous areas.
Innovation Solution
A multi-layer structure is introduced, with foils laminated onto the surface lighting elements, incorporating a conductive contacting element between the foils and the elements, providing mechanical and corrosion protection, and enabling flexible and robust electrical connections through a wiring carrier with functional coatings for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If surface lighting elements are made larger to create larger luminous areas, then the illuminated area increases, but the current density distribution becomes non-homogeneous and the elements become more susceptible to mechanical stress and corrosion
Solution Approach 1:
The patent divides the large surface lighting element into multiple smaller modular units that can be interconnected. Each module maintains homogeneous current density distribution independently through its own transparent contacts, while the modular arrangement allows creation of larger overall luminous areas without compromising the electrical performance of individual modules.
2Area of stationary object
If surface lighting elements are made larger to create larger luminous areas, then the illuminated area increases, but the elements become more susceptible to mechanical stress and corrosion
Solution Approach 1:
The patent employs flexible encapsulation films and protective coatings on the surface lighting elements. These thin film structures provide mechanical protection against stress and environmental corrosion while maintaining the flexibility and large area characteristics of the lighting modules.
3Reliability
If transparent contacts are used to achieve homogeneous current density distribution, then the current distribution improves, but the maximum luminescent surface size is limited by the contact conductivity
Solution Approach 1:
The patent segments the large luminescent surface into multiple smaller units, each equipped with its own transparent contacts optimized for homogeneous current distribution. This segmentation allows each contact to effectively serve a limited area while the collective arrangement of multiple modules achieves the desired large overall luminescent surface.
4Adaptability or versatility
If surface lighting elements are made flexible with thin substrates, then the adaptability for new applications increases, but the elements become more sensitive to mechanical stress and harder to connect robustly
Solution Approach 1:
The patent uses flexible encapsulation films and protective coatings that provide mechanical reinforcement to thin substrate-based surface lighting elements. These films maintain the flexibility needed for new applications while protecting against mechanical stress and enabling more robust connections.
Solution Approach 2:
The patent creates composite structures by combining thin flexible substrates with protective encapsulation layers and interconnection elements. This composite approach maintains the adaptability of thin flexible materials while adding the mechanical strength and connection robustness needed for reliable operation.
Data Source
Figure 1~3(D)
Figure 4~6
Figure 7(A)~8
AI summary
A light module (1) with a multilayer structure comprises a surface light element (10, 11, 12, 13, 14), a contact element (40; 48, 49) having conductive structures, and a film (30). The film (30) is attached to the surface light element (10-14) over its entire area, such that at least one section of the contact element (40) is arranged between the film (30) and the surface light element (10-14).