OLED Edge Encapsulation for Marginless Luminous Surfaces
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Solution Overview
Problem
Conventional organic light-emitting diodes (OLEDs) often have luminous surfaces surrounded by non-luminous, dark margins from the substrate, making it difficult to create a continuous and uninterrupted large-area luminous surface when multiple OLEDs are placed together.
Innovation Solution
The organic light-emitting diode design features an organic layer sequence that extends to the substrate edges, with a continuous encapsulation covering the edges, allowing the luminous surface to appear marginless and enabling the formation of a continuous, uninterrupted large-area luminous surface when multiple units are tiled.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the organic layer sequence is extended to the substrate edges, then the luminous surface area is increased and the marginless appearance is achieved, but the risk of contamination and degradation at the edges is increased
Solution Approach 1:
The encapsulation layer is applied in advance to cover and protect the organic layer sequence before the device is assembled and operated. This preliminary protective action prevents contamination and degradation at the edges, allowing the organic layer to extend to the substrate edges while maintaining reliability.
Solution Approach 2:
The encapsulation layer acts as an intermediary between the organic layer sequence and the external environment. It provides a protective barrier that isolates the organic materials from oxygen and moisture, enabling the luminous surface to extend to the edges without compromising the stability of the organic layers.
2Area of stationary object
If multiple OLEDs are placed together to form a large-area luminous surface, then the total luminous area is increased, but the dark margins between individual OLEDs create visual interruptions
Solution Approach 1:
Multiple OLED units are merged together with their encapsulation layers forming a continuous protective barrier. The encapsulation extends over the edges and can be made continuous across multiple units, creating a unified structure that eliminates visual interruptions and achieves a seamless large-area luminous surface.
Solution Approach 2:
The solution moves from a two-dimensional planar arrangement to a three-dimensional structure where the encapsulation layer wraps around the edges. This dimensional change allows the encapsulation to bridge gaps between adjacent OLEDs, creating continuous luminous surfaces when multiple units are tiled together.
3Length of moving object
If the organic layer sequence is made thin to reduce device thickness, then the flexibility and rollability are improved, but the manufacturing precision requirements are increased
Solution Approach 1:
The patent employs flexible substrate materials and thin-film encapsulation techniques that enable the OLED to be rolled and bent. The encapsulation layer is applied as a thin film that conformally coats the substrate, maintaining protection even when the device is flexed or rolled into compact forms.
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 a seamless, marginless appearance of the luminous surface, enhancing the visual effect and enabling the creation of large, continuous luminous areas without the interruption typically seen with conventional OLEDs.
Implementation Method 1
The organic layer sequence includes at least one emitter layer that generates electromagnetic radiation, advantageously radiation visible to human beings, during intended operation of the light-emitting diode
Data Source
AI summary
An organic light-emitting diode provides a substrate having a top side and one or a plurality of substrate side surfaces running transversely to the top side and connected thereto via a substrate edge; and an organic layer sequence applied to the top side with an emitter layer, which generates electromagnetic radiation coupled out from the diode via a luminous surface during intended operation of the diode. In a plan view of the luminous surface, the sequence adjoins at least a partial region of substrate edge(s), and in the region the luminous surface extends at least as far as the corresponding edge. An encapsulation formed in an uninterrupted and continuous fashion is applied to the sequence. The encapsulation, at least in the region of the edge adjoining the sequence, is led onto the associated substrate side surface, at least partly covers the latter and is in direct contact with the surface.