OLED area illumination light source having flexible substrate on a support

• US 20030222578A1
• Filed: 05/28/2002
• Published: 12/04/2003
• Est. Priority Date: 05/28/2002
• Status: Active Grant

• Current Assignee: Global OLED Technology LLC (LG Display Co., Ltd.)
• Original Assignee: Eastman Kodak Company
• Inventors: Cok, Ronald S.
• Granted Patent: US 6,787,990 B2
• Time in Patent Office: Days
• US Class Current: 313/512
• CPC Class Codes: F21K 9/23 Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
• CPC Class Codes: F21V 3/00 Globes; Bowls; Cover glasses with refracting properties F21V5/00; with reflecting properties F21V7/00; characterised by cooling arrangements F21V29/506
• CPC Class Codes: F21Y 2105/00 Planar light sources
• CPC Class Codes: F21Y 2115/15 Organic light-emitting diodes [OLED]
• CPC Class Codes: H01R 12/7076 for connection between PCB and component, e.g. display
• CPC Class Codes: H01R 13/514 composed as a modular blocks or assembly, i.e. composed of co-operating parts provided with contact members or holding contact members between them
• CPC Class Codes: H01R 33/205 secured to structure or printed circuit board
• CPC Class Codes: H10K 2102/311 Flexible OLED
• CPC Class Codes: Y02B 20/30 Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]
• CPC Class Codes: Y10T 428/3187 Amide-aldehyde

Abstract

A solid-state area illumination light source includes a rigid support; a flexible substrate attached to the rigid support; an organic light emitting diode (OLED) layer deposited on the flexible substrate, the organic light emitting diode layer including first and second electrodes for providing electrical power to the OLED layer; an encapsulating cover covering the OLED layer, first and second conductors electrically connected to the first and second electrodes, and extending beyond the encapsulating cover for making electrical contact to the first and second electrodes by an external power source; and a base connected to the rigid support, the base being adapted to be removably received by a socket and having first electrical contacts for making electrical connection to the first and second conductors of the light source, and second electrical contacts for making electrical connection to conductors in the socket.

Claims

1. A solid-state area illumination light source, comprising:

a) a rigid support;

b) a flexible substrate attached to the rigid support;

c) an organic light emitting diode (OLED) layer deposited on the flexible substrate, the organic light emitting diode layer including first and second electrodes for providing electrical power to the OLED layer,

d) an encapsulating cover covering the OLED layer;

e) first and second conductors electrically connected to the first and second electrodes, and extending beyond the encapsulating cover for making electrical contact to the first and second electrodes by an external power source; and

f) a base connected to the rigid support, the base being adapted to be removably received by a socket and having first electrical contacts for making electrical connection to the first and second conductors of the light source, and second electrical contacts for making electrical connection to conductors in the socket.

2. The light source claimed in claim 1, wherein the support is a frame.

3. The light source claimed in claim 1, wherein the support is a rigid sheet coextensive with the flexible substrate.

4. The light source claimed in claim 1, wherein the rigid support holds the flexible substrate in a flat plane.

5. The light source claimed in claim 1, wherein the rigid support holds the flexible substrate in a curved configuration.

6. The light source claimed in claim 5, wherein the curved configuration is cylindrical, spiral, or conical.

7. The light source claimed in claim 1, wherein the base comprises one or more tab portions extending from the rigid support;

the first and second conductors being located on the tab portion(s).

8. The light source claimed in claim 7, wherein the tab portion(s) include an orientation feature for orienting the light source in a socket.

9. The light source claimed in claim 7, wherein the first and second conductors are located on both sides of the tab portion(s), whereby the light source can be inserted into a socket in either of two orientations.

10. The light source claimed in claim 7, wherein the tab portions are located at opposite edges of the substrate.

11. The light source claimed in claim 1, wherein the light source emits light from one side and the base is located on an opposite side of the light source.

12. The light source claimed in claim 1, wherein the encapsulating cover is a coated layer.

13. The light source claimed in claim 1, wherein the encapsulating cover is a hermetically sealed cover plate.

14. The light source claimed in claim 1, wherein the OLED layer is continuous over the substrate.

15. The light source claimed in claim 1, wherein the light source operates on standard power.

16. The light source claimed in claim 15, wherein the standard power is elected from the group consisting of 110 volt AC, 220 volt AC, 24 volt DC, 12 volt DC, and 6 volt DC.

17. The light source claimed in claim 1, wherein the support is transparent and light is emitted through the support.

18. The light source claimed in claim 1, wherein the rigid support also functions as the encapsulating cover.

19. The light source claimed in claim 1, wherein the rigid support is transparent.

20. The light source claimed in claim 1, further comprising a transparent or translucent housing surrounding the support.

21. The light source claimed in claim 20, wherein the housing has the shape of a standard light bulb.

22. The light source claimed in claim 1, wherein the base is adapted to be received by and make electrical contact with a standard light socket.

23. The light source claimed in claim 1, further comprising:

a converter connected to the first and second conductors for converting power from an external power source to a form useable by the OLED layer.

24. The light source claimed in claim 23, wherein the base is adapted to be received by and make electrical contact with a standard light socket, and wherein the converter is located in the base.

25. The light source claimed in claim 24, wherein the converter converts AC line voltage to a voltage useable by the OLED layer.

26. The light source claimed in claim 22, wherein the standard light socket is an American style screw in light bulb contact or a European style bayonet pin-type light bulb contact.

27. The light source claimed in claim 3, wherein the rigid support is reflective.

28. A method of manufacturing a solid-state area illumination light source, comprising the steps of:

a) depositing an organic light emitting diode (OLED) layer on a flexible substrate, the organic light emitting diode layer including first and second electrodes for providing electrical power to the OLED layer, first and second conductors electrically connected to the first and second electrodes, and an encapsulating cover, the first and second electrodes extending beyond the encapsulating cover for making electrical contact to the first and second electrodes by an external power source;

b) attaching the flexible substrate to a rigid support; and

c) providing a base connected to the rigid support, the base being adapted to be removably received by a socket and having first electrical contacts for making electrical connection to the first and second conductors of the light source, and second electrical contacts for making electrical connection to conductors in the socket.

29. The method claimed in claim 28, wherein the rigid support is a frame.

30. The method claimed in claim 28, wherein the rigid support is a rigid sheet coextensive with the flexible substrate.

31. The method claimed in claim 28, wherein the rigid support holds the flexible substrate in a flat plane.

32. The method claimed in claim 28, wherein the rigid support holds the flexible substrate in a curved configuration.

33. The method claimed in claim 32, wherein the curved configuration is cylindrical, spiral, or conical.

34. The method claimed in claim 28, wherein the base comprises one or more tab portions extending from the rigid support;

the first and second conductors being located on the tab portion(s).

35. The method claimed in claim 34, wherein the tab portion(s) include an orientation feature for orienting the light source in a socket.

36. The method claimed in claim 34, wherein the first and second conductors are located on both sides of the tab portion(s), whereby the light source can be inserted into a socket in either of two orientations.

37. The method claimed in claim 34, wherein the tab portions are located at opposite edges of the substrate.

38. The method claimed in claim 28, wherein the light source emits light from one side and the base is located on an opposite side of the light source.

39. The method claimed in claim 28, wherein the encapsulating cover is a coated layer.

40. The method claimed in claim 28, wherein the encapsulating cover is a hermetically sealed cover plate.

41. The method claimed in claim 28, wherein the OLED layer is continuous over the substrate.

42. The method claimed in claim 28, wherein the rigid support is transparent and light is emitted through the support.

43. The method claimed in claim 28, wherein the rigid support also functions as the encapsulating cover.

44. The method claimed in claim 43, wherein the rigid support is transparent.

45. The method claimed in claim 28, further comprising the step of attaching a transparent or translucent housing surrounding the rigid support.

46. The method claimed in claim 45, wherein the housing has the shape of a standard light bulb.

47. The method claimed in claim 28, wherein the base is adapted to be received by and make electrical contact with a standard light socket.

48. The method claimed in claim 28, further comprising the step of providing a converter connected to the first and second conductors for converting power from an external power source to a form useable by the OLED layer.

49. The method claimed in claim 48, wherein the converter is located in the base.

50. The method claimed in claim 49, wherein the converter converts AC line voltage to a voltage useable by the OLED layer.

51. The method claimed in claim 50,wherein the standard light socket is an American style screw in light bulb contact or a European style bayonet pin-type light bulb contact.

52. The method claimed in claim 30, wherein the rigid support is reflective.

53. The method claimed in claim 28, wherein the flexible substrate is a web supplied on a roll.

54. The method claimed in claim 29, wherein the frame is attached to the flexible substrate by injection molding the frame around the substrate.

55. The method claimed in claim 30, wherein the flexible substrate is attached to the rigid support by laminating with an adhesive.