Scored Substrate for OLED Light Outcoupling
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Solution Overview
Problem
Current methods for enhancing light outcoupling in OLED devices, such as using light extraction blocks or microlens arrays, often result in increased thickness and weight, which are undesirable for thin and flexible OLED applications, and involve complex and costly manufacturing processes.
Innovation Solution
A method involving mechanical scoring of a substrate to create non-planar surfaces with arrays of mesas or grooves, which are optically coupled with OLEDs, allowing for efficient light outcoupling without adding thickness or weight, using techniques like roll-to-roll processing and specific scoring parameters to achieve high refractive index matching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If light extraction blocks or microlens arrays are used to enhance light outcoupling, then light outcoupling efficiency is improved, but device thickness and weight increase
Solution Approach 1:
The patent transitions from three-dimensional light extraction blocks to two-dimensional surface patterns (grooves and mesas) on the substrate. This dimensional reduction eliminates the need for thick extraction structures while maintaining light outcoupling enhancement through surface geometry modification that affects light propagation paths.
Solution Approach 2:
The patent replaces complex optical components (microlens arrays and light extraction blocks) with simple mechanical surface patterning (scored grooves and mesas). This substitution uses geometric surface features rather than bulky optical elements to achieve the same light management function, reducing device thickness.
2Loss of energy
If light extraction blocks or microlens arrays are used to enhance light outcoupling, then light outcoupling efficiency is improved, but device weight increases
Solution Approach 1:
The patent extracts the light management function from separate heavy components (extraction blocks and microlens arrays) and integrates it directly into the substrate surface through scoring. This integration eliminates the weight of additional optical components while maintaining the light outcoupling function.
Solution Approach 2:
The patent merges the light outcoupling function with the substrate itself by creating surface patterns during substrate fabrication. This consolidation eliminates the need for separate light extraction components, reducing overall device weight while achieving the desired optical performance.
3Loss of energy
If traditional light extraction methods are used, then light outcoupling is enhanced, but manufacturing complexity and cost increase
Solution Approach 1:
The patent performs light extraction pattern creation during the substrate fabrication process itself, before OLED deposition. This preliminary action integrates light management into the base substrate manufacturing, eliminating subsequent complex assembly steps required for separate extraction components.
Solution Approach 2:
The patent changes the manufacturing approach from assembling complex optical components to applying simple surface scoring with controlled parameters (groove depth, width, spacing). This parameter-based control simplifies the manufacturing process while achieving consistent light outcoupling enhancement.
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 achieves up to double the light outcoupling efficacy compared to traditional methods, maintaining the thin and flexible nature of OLED devices while reducing manufacturing complexity and cost.
Implementation Method 1
achieves up to double the light outcoupling efficacy
Implementation Method 2
high refractive index matching
Data Source
AI summary
Devices and techniques are provided in which a transparent substrate is scored to provide a non-planar surface on one side of the substrate. An OLED is then disposed on the other side of the scored substrate and optically coupled to the substrate. The scored surface provides improvements to outcoupling of light generated by the OLED, with little or no additional thickness relative to the OLED alone.