Organic EL Electrode Taking-Out via Folded Back Design
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Solution Overview
Problem
Existing organic EL device manufacturing methods are inefficient due to the complexity of forming electrode taking-out portions, particularly when using the roll-to-roll process.
Innovation Solution
An organic EL device design where the electrode layer extends beyond the organic layer's region on the substrate and is folded back to create the electrode taking-out portion, utilizing an insulating layer and a sealing member to prevent short-circuiting and moisture ingress, allowing for efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the anode and light emitting layer are patterned in complicated shapes to form 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 electrode taking-out portion is formed. This segmentation allows the electrode pattern to be simplified in the peripheral region, enabling efficient manufacturing while maintaining proper electrode formation for device operation.
2Reliability
If the electrode layer extends to the outer peripheral side to form an electrode taking-out portion, then electrical connection can be established, but short-circuiting may occur with the substrate
Solution Approach 1:
An insulating layer is introduced as an intermediary between the extended electrode layer and the substrate in the peripheral region. This insulating layer prevents direct contact between the electrode and substrate, eliminating the risk of short-circuiting while allowing the electrode to extend for electrical connection.
Solution Approach 2:
The problem of electrode-substrate short-circuiting is solved by adding a new dimensional layer (the insulating layer) between the electrode and substrate. This vertical separation in the third dimension prevents harmful electrical contact while maintaining the horizontal extension needed for electrode taking-out.
3Reliability
If the organic layer is formed only in a specific region, then the light emitting function is achieved, but the electrode layer cannot extend beyond this region
Solution Approach 1:
The organic layer is selectively formed only in the light-emitting region, while the electrode layer is formed in both the light-emitting region and the peripheral region. This local differentiation allows the electrode to extend for taking-out purposes without requiring the organic layer to be present everywhere, simplifying the overall manufacturing process.
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 design simplifies the formation of the electrode taking-out portion and enhances the manufacturing efficiency of organic EL devices, enabling flexible and reliable production, including the use of flexible substrates and roll-to-roll processing.
Implementation Method 1
a second substrate joined to the electrode layer by an adhesive layer
Implementation Method 2
a portion of the electrode layer is provided on the first substrate through an insulating layer
Implementation Method 3
The extended electrode layer is folded back together with the insulating layer to a side opposite to the second substrate, to constitute an electrode taking-out portion
Data Source
AI summary
An organic EL device includes a first substrate having electrical conductivity, an organic layer formed on the first substrate, an electrode layer formed on the organic layer, and a second substrate joined to the electrode layer by an adhesive layer. In a region of a peripheral portion of the first substrate, the organic layer is not formed, and a portion of the electrode layer is provided on the first substrate through an insulating layer so as to extend to an outer peripheral side of a region where the organic layer is present. The extended electrode layer is folded back together with the insulating layer to a side opposite to the second substrate, to constitute an electrode taking-out portion.