OLED Spacer Design for Mechanical Stability and Uniform Luminance

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Solution Overview

Problem

Large-area organic light-emitting diodes (OLEDs) face mechanical damage due to the weight and external forces on the covering layer, which can lead to inhomogeneous luminance distribution and increased short circuit risks, and existing solutions either increase the device thickness or use spacers that cause additional damage.

Innovation Solution

An optoelectronic device with a covering layer, a first electrode having conductor tracks with branching points, and spacers arranged on these points, where the functional layer stack is placed between the covering layer and the spacers, providing mechanical stability and uniform luminance distribution without direct contact between the covering layer and the layer stack.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the distance between the covering layer and the layer stack is enlarged to avoid damage, then the mechanical stability is improved, but the overall thickness of the diode increases

Engineering Contradiction:

Improvemechanical stabilityVSAvoidoverall thickness

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The patent divides the supporting function into multiple spacers distributed at branching points rather than using a single continuous support structure. This segmentation allows the covering layer to be supported at critical stress points while maintaining thin overall device profile.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spacers are strategically positioned at branching points where mechanical stress is most likely to occur. This local reinforcement approach provides mechanical stability exactly where needed without increasing the overall device thickness uniformly across the entire structure.

Inventive Principle:

Principle #3Local quality

2Reliability

If randomly distributed spacers are used to support the covering layer, then the mechanical stability is improved, but the layer stack is damaged due to direct pressure from spacers

Engineering Contradiction:

Improvemechanical stabilityVSAvoiddamage to layer stack

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces the covering layer as an intermediary element between the spacers and the layer stack. The covering layer distributes the mechanical load from the spacers across a wider area, preventing direct pressure concentration on the layer stack while maintaining structural support.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The covering layer acts as a pre-positioned cushioning element that absorbs and distributes mechanical stresses before they can reach the layer stack. This protective layer is in place before external forces are applied, preventing damage in advance.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If spacers press directly onto the layer stack to maintain device stability, then the mechanical stability is improved, but the luminance distribution becomes inhomogeneous and short circuit risk increases

Engineering Contradiction:

Improvedevice stabilityVSAvoidluminance distribution uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The covering layer serves as a mediator that decouples the spacers from direct contact with the layer stack. This intermediary structure allows the spacers to provide mechanical stability while the covering layer ensures uniform pressure distribution, preventing luminance inhomogeneity and short circuit risks.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The spacers are positioned at branching points rather than being randomly distributed. This specific positioning, combined with the covering layer, creates localized support points that do not create pressure concentrations on the layer stack, maintaining uniform luminance distribution while providing necessary mechanical stability.

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 enhances mechanical stability, maintains a thin device profile, and ensures a uniform luminance distribution while minimizing the risk of short circuits, even under external forces, by using spacers that cover branching points and are spaced laterally, thus reducing the area affected by external pressure.

Implementation Method 1

The functional layer stack has an organic active layer that generates electromagnetic radiation

Methodology Applied

Scientific EffectElectroluminescence: Electroluminescence

Data Source

PatentUS10177340B2Optoelectronic device and method of producing an optoelectronic device

Publication Date: 2019.01.08 DOLYA HOLDCO 5 LTD

AI summary

An optoelectronic device includes a covering layer, a first electrode, a functional layer stack arranged between the covering layer and the first electrode and a plurality of spacers, wherein the functional layer stack has an organic active layer that generates electromagnetic radiation; the first electrode has conductor tracks with branching points, the spacers are each arranged on one of the branching points, and the functional layer stack is arranged in places between the covering layer and the spacers.