Resilient Body 3D Luminous Face OLED Module
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Solution Overview
Problem
Current methods for producing organic light-emitting diodes (OLEDs) on 3D surfaces are unsuitable due to inhomogeneous deposition and thickness variations, leading to poor performance and luminance gradients, as existing techniques struggle with shadowing and achieving uniform coatings on complex shapes.
Innovation Solution
A light-emitting module comprising a resilient body with a light-deviating region and a free-lying surface, which can be configured in any 3D shape, is used in conjunction with a 2D or 2.5D light-emitting component, allowing for a 3D luminous face that is mechanically flexible and elastically deformable, enabling uniform light distribution and complex surface designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If physical vapor deposition is used for coating 3D surfaces, then homogeneous surface-wide coatings can be achieved for flat substrates, but shadowing occurs and coating becomes inhomogeneous for complex 3D objects
Solution Approach 1:
The patent divides the 3D object into multiple flat or moderately curved surfaces that can be individually coated. By segmenting the complex 3D surface into manageable planar sections, each surface can be coated uniformly using physical vapor deposition without shadowing effects, then assembled to form the complete 3D structure.
Solution Approach 2:
The patent transitions from attempting to coat a complex 3D surface directly to coating multiple 2D or 2.5D surfaces and assembling them in 3D space. This dimensionality approach allows each surface to be coated in its optimal 2D configuration while the final assembly creates the desired 3D luminous object.
2Ease of manufacture
If organic functional layers are applied with inaccurate thickness definition, then production can be simplified, but luminance gradients and poor OLED performance occur
Solution Approach 1:
The patent segments the OLED structure into multiple planar or moderately curved layers, each of which can be coated with precise thickness control using physical vapor deposition. This segmentation allows standard coating techniques to achieve accurate thickness definition on each surface while the overall structure achieves 3D configuration.
Solution Approach 2:
The patent applies organic functional layers with accurately defined thickness to flat or moderately curved surfaces before final 3D assembly. This preliminary coating action ensures precise thickness control is achieved while surfaces are still accessible to line-of-sight deposition methods, avoiding the need for complex in-situ coating on final 3D structures.
3Shape
If 2D OLEDs are assembled to form 3D bodies, then 3D luminous structures can be created, but non-luminous edge regions remain at the edges of the 3D object
Solution Approach 1:
The patent applies light-deviating structures selectively at the edges and boundaries of the 3D luminous object. These local light-deviating elements redirect light that would otherwise escape at edges back into the luminous volume, ensuring uniform luminous coverage throughout the entire 3D structure including previously dark edge regions.
Solution Approach 2:
The patent introduces light-deviating structures as intermediary elements between the light-emitting OLED surfaces and the external environment. These intermediaries redirect and distribute light uniformly across the 3D structure, eliminating dark edges and ensuring complete luminous coverage of the final object.
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 provides a 3D luminous face with improved uniformity and flexibility, allowing for precise deformation and representation of information, while maintaining sufficient geometrical stability and efficient light distribution, overcoming the limitations of existing 2D and 2.5D OLEDs on complex surfaces.
Implementation Method 1
The resilient body includes at least one light-deviating region and a free-lying surface
Data Source
AI summary
A light-emitting module including a light-emitting component and a resilient body is provided. The light-emitting component includes a light-emitting layer structure for generating light and includes a light-emitting main face through which the generated light leaves the light-emitting component. The resilient body, which is arranged over the light-emitting main face, is connected firmly to the light-emitting component, includes at least one light-deviating region, and includes a free-lying surface which includes at least one surface element, which lies at a distance greater than or equal to 4 mm from the light-emitting layer structure.