Ultrathin OLED Panel with Bendable FPC Extension Tab
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Solution Overview
Problem
OLED lighting panels face challenges in achieving thin, flexible designs with versatile electrical connection configurations, leading to increased thickness and complexity in manufacturing due to the need for different manufacturing processes for various connection setups.
Innovation Solution
A flexible lighting panel with a bendable extension tab on a flexible printed circuit board, allowing for three modes of electrical connection: unbent, partially bent, and fully folded configurations, enabling electrical connections to be made from different orientations without compromising thickness or manufacturing simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical connections are made from the edge or opposite face of the OLED unit, then connection versatility is improved, but panel thickness increases
Solution Approach 1:
The patent applies dimensionality change by routing electrical connections through the edge of the substrate rather than through the thickness of the panel. The conductive traces are positioned at the peripheral edge of the substrate, allowing electrical access from the side dimension rather than requiring increased panel thickness. This enables versatile connection configurations while maintaining ultrathin panel profile.
2Adaptability or versatility
If different connection configurations are supported, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent implements universality by designing a single substrate structure with conductive traces positioned at the edge that can serve multiple connection configurations. The same edge-positioned trace design enables connections from the edge, opposite face, or other orientations without requiring different manufacturing processes. This multi-functional design simplifies manufacturing while providing connection versatility.
Solution Approach 2:
The patent applies dynamics by making the substrate flexible rather than rigid. This flexibility allows the substrate to be bent or folded to achieve different connection orientations during assembly, while the manufacturing process remains consistent. The dynamic, flexible substrate enables multiple connection configurations without requiring complex manufacturing for each specific orientation.
3Ease of manufacture
If electrode contact pads are located in non-emissive border areas, then electrical connection is simplified, but aesthetic appeal deteriorates
Solution Approach 1:
The patent extracts the contact pads from the visible emissive area and positions them at the edge of the substrate where they are not visible during normal operation. By locating the electrical connection elements at the peripheral edge rather than in border areas around the emissive region, the design maintains aesthetic appeal while preserving manufacturing simplicity.
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 results in an ultrathin, flexible lighting panel with versatile electrical connection options, enhancing aesthetic appeal and adaptability while maintaining manufacturing ease, and providing protection and safety features.
Implementation Method 1
OLED technology to generate light... at least one organic electroluminescent layer between two electrodes on a substrate and would be encapsulated to protect the electroluminescent layer(s)
Data Source
AI summary
A flexible lighting panel comprising a light-emitting unit with electrical contact pads on a flexible substrate; a flat flexible printed circuit board with a bendable extension tab, wherein the circuit board is located on the opposite side of the light-emitting unit from the substrate; the area of the circuit board, not including the extension tab, is the same or greater than and overlaps the emissive area of the light-emitting unit; and the circuit board has at least two flat electrical connectors in electrical contact with the contact pads of the light-emitting unit; the flat electrical connectors extending along the extension tab of the circuit board for connection to a power source. The light emitting unit can be an OLED. The extension tab can be bent so that the flat electrical connections become accessible in different orientations. The panel can be ultrathin.