Self-Supporting 3D OLED Lamps via Segmented Substrates
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Solution Overview
Problem
Existing organic light emitting devices (OLEDs) lack the ability to maintain a three-dimensional shape without external constraints, as they are typically flat and lack the necessary flexural rigidity to conform to complex geometries while maintaining functionality and avoiding strain or damage.
Innovation Solution
A flexible OLED device with structurally weakened regions, such as cuts, scores, or perforations, is integrated into a substrate that can fold or bend into three-dimensional shapes, maintaining sufficient flexural rigidity to support the shape without external fixtures, using materials like metal foil, plastic, or glass with appropriate thickness and insulating layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible OLED device is made to conform to three-dimensional shapes, then adaptability and shape versatility are improved, but the device lacks sufficient flexural rigidity to maintain the shape without external fixtures
Solution Approach 1:
The substrate is divided into multiple regions by introducing structurally weakened regions (cuts, scores, or perforations). These segmented regions can independently bend or fold along predetermined lines, allowing the overall device to conform to three-dimensional shapes while maintaining sufficient rigidity in non-cut regions to support the formed configuration without external fixtures.
Solution Approach 2:
The device utilizes a flexible substrate with controlled structural features that provide both flexibility for shaping and rigidity for support. The combination of intact substrate regions (providing rigidity) and structurally weakened regions (providing flexibility) creates a self-supporting structure that can maintain three-dimensional configurations.
2Adaptability or versatility
If structurally weakened regions are introduced to enable three-dimensional shaping, then shape adaptability is improved, but device reliability may worsen due to potential damage at cut or score regions
Solution Approach 1:
The structurally weakened regions (cuts, scores, or perforations) are created in advance during the manufacturing process, before the device is assembled or deployed. This preliminary action allows the device to be pre-configured with predetermined bending or folding lines, enabling reliable three-dimensional shaping while minimizing stress concentrations that could lead to failure during operation.
3Ease of operation
If the substrate is made thinner to improve flexibility, then ease of shaping is improved, but the device complexity increases due to need for additional support structures
Solution Approach 1:
Rather than using a thin uniform substrate that would require additional support structures, the invention segments the substrate itself by introducing cuts, scores, or perforations. This segmentation allows thin regions to be flexible for shaping while intact regions provide structural support, eliminating the need for separate support structures and reducing overall device 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
The flexible OLED devices can transform into three-dimensional configurations like conical spirals or origami lamps, maintaining light output and optical performance while being self-supporting and adaptable, suitable for decorative and commercial lighting applications.
Implementation Method 1
OLEDs make use of thin organic films that emit light when voltage is applied across the device
Data Source
AI summary
Novel three dimensional OLEDs are provided. The OLEDs have two configurations, and are self supporting in the three dimensional configuration without the need for any external supports.