OLED Series Interconnects Redirecting Light to Eliminate Black Lines
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Solution Overview
Problem
OLED devices with segmented OLEDs connected in series suffer from visible black lines due to non-emissive gaps between segments, and existing solutions require complex and costly manufacturing processes to align and glue electroluminescent elements, leading to inefficiencies in light emission and increased manufacturing effort.
Innovation Solution
The use of an interconnect region with a first isolating layer of non-conducting material and a conductive layer with suitable optical properties to redirect light emitted by adjacent OLED segments, eliminating the need for non-emissive gaps and simplifying the manufacturing process by reducing the number of masks required and allowing for easier alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If OLED segments are connected in series on a substrate, then current requirements are reduced, but visible black lines appear due to non-emissive gaps between segments
Solution Approach 1:
The patent converts the harmful non-emissive gaps into beneficial light-emitting interconnect regions by applying conductive material with light-scattering properties. The gaps between OLED segments, which originally caused visible black lines, are transformed into regions that redirect trapped light within the substrate toward the environment, making them appear as part of the light-emitting area.
Solution Approach 2:
The patent changes the optical parameters of the interconnect regions by applying conductive material with specific light-scattering properties. This alters how light propagates and exits from these regions, transforming them from dark non-emissive areas to bright regions that contribute to overall light emission and homogeneous brightness appearance.
2Area of stationary object
If separate electroluminescent elements are glued together to form large area light sources, then gaps between elements can be filled, but manufacturing complexity and effort increase significantly
Solution Approach 1:
The patent merges multiple functions into the interconnect regions: electrical connection between segments, structural support, and light redirection. By applying conductive material with light-scattering properties in these regions, the patent combines electrical connectivity and optical functionality into a single integrated solution, eliminating the need for separate alignment and gluing processes.
Solution Approach 2:
The interconnect regions serve multiple purposes simultaneously: they provide electrical connection between series-connected OLED segments, provide structural support, and redirect trapped light to eliminate visible gaps. This multi-functionality simplifies the overall device structure and manufacturing process compared to separate alignment and gluing approaches.
3Manufacturing precision
If multiple masks process is used to structure electrodes for series connection, then precise alignment is achieved, but manufacturing time and cost increase
Solution Approach 1:
The patent merges the electrode structuring and interconnect formation into a single process step. By applying conductive material that simultaneously creates electrical connections and defines electrode patterns, the patent eliminates the need for multiple sequential mask processes, thereby improving manufacturing efficiency while maintaining precision.
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 solution achieves homogeneous brightness across the OLED device by redirecting trapped light from the substrate, making the interconnect regions appear as part of the light-emitting area, thereby eliminating visible black lines and simplifying the manufacturing process, reducing costs and effort.
Implementation Method 1
a conductive layer of an electrically conducting material to connect the counter electrode of the OLED segment to the substrate electrode of the adjacent OLED segment, wherein the electrically non-conducting material and/or the conducting material is suitable to redirect the light emitted by the adjacent OLED segments out of the substrate to emit light from the interconnect regions into the environment
Data Source
AI summary
OLED device (1) comprising a substrate (4) with multiple light emitting OLED segments (5, 6, 7) on top of the substrate (4) each comprising an electroluminescent layer stack (6) of at least an organic light-emitting layer sandwiched between a substrate electrode (5) facing towards the substrate (4) and a counter electrode (7), which are connected in series and are separated from the adjacent OLED segment (5, 6, 7) by an interconnect region (3) located between the adjacent OLED segments comprising a first isolating layer (10) of an electrically non-conducting material between the substrate electrodes (5) of adjacent OLED segments to electrically isolate the adjacent substrate electrodes (5) from each other and a conductive layer (9) of an electrically conducting material to connect the counter electrode (7) of the OLED segment to the substrate electrode (5) of the adjacent OLED segment, wherein the electrically non-conducting material and/or the conducting material is suitable to redirect the light emitted by the adjacent OLED segments out of the substrate (4) to emit light (81) from the interconnect regions (3).