Segmented Flexible OLED Lighting Module for Yield Improvement
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Solution Overview
Problem
OLED lighting modules face high costs and low yield due to expensive organic materials and manufacturing challenges, particularly with flexible substrates being susceptible to particles that can short anode and cathode, leading to reduced device lifetime and efficiency.
Innovation Solution
The solution involves a high-yield, low-cost large-area flexible OLED lighting module design where OLED panels with separated substrates are electrically connected via a flexible printed circuit sheet, allowing for external access and incorporating a light extraction layer, sensors, and a thin-film encapsulation layer, enabling efficient assembly and improved yield by screening out defective panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If OLED panels are assembled on a single large substrate, then manufacturing cost is reduced, but yield decreases due to particle contamination causing short circuits
Solution Approach 1:
The invention divides the large substrate into multiple smaller substrate regions, each capable of independently producing OLED panels. This segmentation allows defective regions to be isolated and discarded without compromising the entire substrate, thereby improving yield while maintaining cost efficiency through large-area manufacturing.
2Adaptability or versatility
If flexible substrates are used for OLED lighting, then device flexibility and novel form factors are achieved, but susceptibility to particle contamination increases, reducing device lifetime
Solution Approach 1:
By segmenting the flexible substrate into multiple smaller regions, the invention reduces the probability of particle contamination affecting the entire device. Each segmented region can be independently encapsulated and protected, maintaining flexibility while improving reliability and lifetime.
3Productivity
If multiple OLED panels are electrically connected on a single substrate, then manufacturing efficiency is improved, but complexity of electrical routing and interconnections increases
Solution Approach 1:
The invention segments the electrical interconnection system by providing separate electrical connections for each OLED panel through the flexible printed circuit board. This approach maintains manufacturing efficiency by processing multiple panels simultaneously while simplifying the electrical routing architecture, as each panel has its own dedicated connection path rather than complex shared routing.
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 reduces manufacturing costs and improves yield by allowing for the use of panels from different substrates, enhancing fill factor and device performance, while maintaining flexibility and efficiency in large-area lighting applications.
Implementation Method 1
an OLED device, placed between the anode and the cathode
Data Source
AI summary
The application relates to the field of OLED lighting, and provides a high-yield low-cost large-area flexible OLED lighting module, a manufacturing method thereof and an OLED lighting luminaire.