OLED Display Light Extraction Film Micro-Lens Array
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Solution Overview
Problem
Conventional OLED display devices suffer from limited luminous flux, optical waveguides between organic layers, and poor optical coupling of substrates, resulting in reduced brightness and light output efficiency.
Innovation Solution
The OLED display device incorporates a flexible substrate with a thin film transistor layer, an OLED light emitting layer, a light extraction film layer with a micro-lens array, and an inorganic protection film layer, where the light extraction film is plasma-polymerized hexamethyl-disiloxane and the micro-lens array is formed through nano-imprint, and the inorganic protection film is zirconium dioxide or titanium dioxide, enhancing optical coupling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional OLED structure is used, then device simplicity is maintained, but light output efficiency is reduced
Solution Approach 1:
A light extraction film layer is introduced as an intermediary component between the OLED light emitting layer and the substrate. This film layer has optimized optical properties (refractive index between 1.3-1.6) that act as a mediator to improve optical coupling and extract more light from the OLED structure, thereby improving light output efficiency without significantly complicating the manufacturing process
Solution Approach 2:
The refractive index of the light extraction film layer is specifically controlled to be between 1.3 and 1.6, which is a key parameter optimization. This parameter change enables better optical matching between layers, reducing total internal reflection and improving light extraction efficiency while maintaining manufacturing feasibility
2Device complexity
If conventional substrate optical coupling is used, then manufacturing complexity is low, but brightness is reduced
Solution Approach 1:
The light extraction film layer serves as an optical intermediary between the OLED light emitting layer and the substrate, improving optical coupling efficiency. This mediator enables better light transmission and reduces reflection losses, thereby increasing brightness without requiring complex manufacturing processes
Solution Approach 2:
The light extraction film layer is made from composite materials such as cyclic olefin copolymer (COc) or cyclic olefin polymer (COP) mixed with silica particles. This composite material approach provides both the required optical properties (refractive index 1.3-1.6) and manufacturing compatibility, achieving enhanced brightness with manageable device complexity
3Device complexity
If organic layers with optical waveguide structure are used, then layer structure is simple, but luminous flux is limited
Solution Approach 1:
The light extraction film layer acts as an intermediary that disrupts the optical waveguide effect in the organic layers. By providing a refractive index mismatch, it enables light that would otherwise be trapped by total internal reflection to escape, thereby increasing luminous flux while maintaining relatively simple layer structure
Solution Approach 2:
The refractive index of the light extraction film layer (1.3-1.6) is specifically chosen to be lower than that of the organic light emitting layer, creating a refractive index gradient that changes the optical confinement conditions. This parameter change allows more light to escape from the organic layers, increasing luminous flux without complicating the layer structure
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 improves light output efficiency by optimizing optical coupling through the micro-lens array and inorganic protection film, addressing the limitations of conventional OLED devices.
Implementation Method 1
a substrate has poor optical coupling
Implementation Method 2
an organic light emitting layer has limited luminous flux
Implementation Method 3
optimizing optical coupling through the micro-lens array
Implementation Method 4
an inorganic protection film layer disposed on the light extraction film layer
Data Source
AI summary
An organic light-emitting diode (OLED) display device is provided in the present invention, including a flexible substrate, a thin film transistor (TFT) layer, an OLED light emitting layer, a light extraction film layer, an inorganic protection film layer, and a packaging film layer. The light extraction film layer includes a first light extraction film layer and a second light extraction film layer. A nano-imprint process is performed on the second light extraction film layer to form a micro-lens array. The present invention also provides a manufacturing method of the OLED display device.