Organic EL Electrode Fold-Back for Roll-to-Roll Manufacturing
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Solution Overview
Problem
Existing organic EL device manufacturing methods face inefficiencies in forming electrode taking-out portions, particularly when using the roll-to-roll process, as they require complex patterning of anodes and light emitting layers.
Innovation Solution
The organic EL device design includes a first substrate with a smoothing layer and an organic layer, where the organic layer is not formed in peripheral regions, allowing the first electrode layer to be folded back and the second electrode layer, along with an insulating layer, to extend and form taking-out portions, simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the anode and light emitting layer are formed by patterning in complicated shapes to provide an electrode taking-out portion, then the electrode taking-out portion can be formed, but the manufacturing efficiency decreases
Solution Approach 1:
The device is divided into a light-emitting region where the organic layer is formed and a non-light-emitting peripheral region where the organic layer is not formed. This segmentation allows the electrode taking-out portion to be formed in the peripheral region without requiring complicated patterning of the light emitting layer, thereby improving manufacturing efficiency while still providing functional electrode take-out capability.
Solution Approach 2:
The electrode taking-out function is extracted from the light-emitting region and relocated to the peripheral region. By forming the electrode taking-out portion in the peripheral region where the organic layer is not formed, the patent eliminates the need for complicated patterning processes in the light-emitting area, thus improving manufacturing efficiency.
2Stability of the object's composition
If the organic layer is formed over the entire substrate including peripheral regions, then complete coverage is achieved, but the formation of electrode taking-out portions becomes more complex
Solution Approach 1:
The substrate area is segmented into a light-emitting region with complete organic layer coverage and a peripheral region without organic layer formation. This segmentation maintains complete coverage where needed for light emission while eliminating the complexity of electrode taking-out portion formation in the peripheral region.
Solution Approach 2:
Different regions of the substrate are given different qualities: the light-emitting region has complete organic layer coverage for optimal light emission, while the peripheral region has no organic layer to simplify electrode taking-out portion formation. This local differentiation resolves the contradiction between complete coverage and formation complexity.
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 approach enables efficient and straightforward formation of electrode taking-out portions, facilitating the mass production of organic EL devices using the roll-to-roll process by folding back the insulating and extended electrode layers, thereby improving manufacturing efficiency.
Implementation Method 1
a smoothing layer which smoothes the first electrode layer
Implementation Method 2
a second substrate joined to the second electrode layer by an adhesive layer
Data Source
AI summary
An organic EL device includes a first substrate including a cathode layer and a smoothing layer, an organic layer formed on the cathode layer, an anode layer formed on the organic layer, and a second substrate joined to the anode layer. In a region of a peripheral portion of the first substrate, the organic layer is not formed. The anode layer is provided on the cathode layer through an insulating layer in a portion of the region so as to extend to an outer peripheral side, the extended anode layer is folded back to a side opposite to the second substrate to constitute an anode taking-out portion, and a portion of the cathode layer of the first substrate is folded back to constitute a cathode taking-out portion.