OLED Light Extraction Substrate with Dual-Texture Thin Film

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Solution Overview

Problem

Organic light-emitting devices (OLEDs) face limited light extraction efficiency due to refractive index differences at the interface between thin film layers and substrates, leading to high light loss, which complicates the manufacturing process and increases costs when attempting to improve optical efficiency.

Innovation Solution

A light extraction substrate with an oxide or nitride thin film featuring multiple textures is formed on a substrate using atmospheric pressure chemical vapor deposition (APCVD), enhancing light extraction efficiency by creating protrusions and varying refractive indices, thereby improving brightness in displays and illumination systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a light extraction layer is formed via photolithography to improve light extraction efficiency, then optical efficiency is improved, but manufacturing cost increases and process complexity increases

Engineering Contradiction:
Improvelight extraction efficiencyVSAvoidprocess complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The patent replaces the photolithography process (mechanical/chemical system) with a self-assembling molecular system. The chiral guest molecules automatically form helical structures within the host matrix upon heating, eliminating the need for complex photolithography equipment and multiple patterning steps while achieving the same light extraction enhancement through helical morphology.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The light extraction layer performs self-organization through the self-assembling behavior of chiral guest molecules. When heated above the melting point, the guest molecules spontaneously form helical structures distributed throughout the host matrix, creating the desired light-scattering morphology without external intervention or complex processing.

Inventive Principle:
Principle #25Self-service

2Loss of energy

If a light extraction layer is formed via photolithography to improve light extraction efficiency, then optical efficiency is improved, but manufacturing cost increases

Engineering Contradiction:
Improvelight extraction efficiencyVSAvoidmanufacturing cost
Core Design Contradiction:
Loss of energyVSEase of manufacture

Solution Approach 1:

The patent replaces expensive photolithography equipment and materials with a simple thermal processing step. The self-assembling molecular system requires only heating above the melting point of the guest molecules, eliminating the need for expensive photolithography tools, photoresists, and cleanroom facilities, thereby dramatically reducing manufacturing costs.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the processing parameter from requiring precise photolithographic patterning to simply controlling temperature above the melting point of guest molecules. This parameter change from optical patterning to thermal processing simplifies manufacturing and reduces equipment costs while achieving the same functional outcome.

Inventive Principle:
Principle #35Parameter changes

3Loss of energy

If polymeric plastic film is patterned and attached to OLED to improve light extraction, then light extraction is enhanced, but refractive index increase is limited and mechanical/thermal endurance is constrained

Engineering Contradiction:
Improvelight extraction efficiencyVSAvoidmechanical and thermal endurance
Core Design Contradiction:
Loss of energyVSReliability

Solution Approach 1:

The patent creates a composite light extraction layer combining a host matrix material (providing mechanical strength and thermal stability) with chiral guest molecules (providing helical morphology for light extraction). This composite structure achieves both high light extraction efficiency through helical scattering and superior reliability from the robust host matrix, overcoming the limitations of pure polymeric films.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent assigns different functional roles to different components: the host matrix provides mechanical and thermal properties throughout the layer, while the guest molecules provide localized helical structures for light scattering. This functional differentiation allows the material to simultaneously achieve high light extraction efficiency and excellent mechanical/thermal endurance.

Inventive Principle:
Principle #3Local quality

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 significantly increases light extraction efficiency, simplifies the manufacturing process, and reduces costs by forming textures naturally during APCVD, resulting in a more efficient and cost-effective OLED with improved brightness.

Implementation Method 1

an oxide or nitride thin film which has a texture formed thereon and absorbs water vapor

Methodology Applied
Scientific EffectAdsorption: Adsorption

Implementation Method 2

atmospheric pressure chemical vapor deposition (APCVD)

Methodology Applied
Scientific EffectChemical vapor deposition: Chemical Vapour Deposition

Data Source

PatentUS9825257B2Light extraction substrate for OLED and method of fabricating the same
Publication Date: 2017.11.21 SAMSUNG CORNING PRECISION MATERIALS CO LTD
  • US9825257B2 patent drawing
  • US9825257B2 patent drawing
  • US9825257B2 patent drawing

AI summary

A light extraction substrate for an organic light-emitting device (OLED) which can improve the brightness of a display or an illumination system to which an OLED is applied by improving light extraction efficiency and a method of manufacturing the same. The light extraction substrate for an OLED includes an oxide or nitride thin film formed on a substrate body. The oxide or nitride thin film includes a base layer formed on the substrate body, a first texture formed on the base layer, the first texture having a plurality of first protrusions which protrude continuously or discontinuously from the base layer, and a second texture having a plurality of second protrusions which protrude continuously or discontinuously from each outer surface of the first protrusions.