WO2013068965A2 - Lighting apparatus and manufacturing method for manufacturing the lighting apparatus - Google Patents

Lighting apparatus and manufacturing method for manufacturing the lighting apparatus Download PDF

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Publication number
WO2013068965A2
WO2013068965A2 PCT/IB2012/056275 IB2012056275W WO2013068965A2 WO 2013068965 A2 WO2013068965 A2 WO 2013068965A2 IB 2012056275 W IB2012056275 W IB 2012056275W WO 2013068965 A2 WO2013068965 A2 WO 2013068965A2
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WO
WIPO (PCT)
Prior art keywords
electrode layer
substrate
layer
manufacturing
reflecting
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Application number
PCT/IB2012/056275
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French (fr)
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WO2013068965A3 (en
Inventor
Holger Schwab
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Koninklijke Philips Electronics N.V.
Philips Intellectual Property & Standards Gmbh
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Application filed by Koninklijke Philips Electronics N.V., Philips Intellectual Property & Standards Gmbh filed Critical Koninklijke Philips Electronics N.V.
Publication of WO2013068965A2 publication Critical patent/WO2013068965A2/en
Publication of WO2013068965A3 publication Critical patent/WO2013068965A3/en

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Classifications

    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K50/00—Organic light-emitting devices
    • H10K50/80—Constructional details
    • H10K50/85—Arrangements for extracting light from the devices
    • H10K50/856—Arrangements for extracting light from the devices comprising reflective means

Definitions

  • the invention relates to a lighting apparatus for producing light.
  • the invention relates further to a manufacturing method, a manufacturing apparatus and a manufacturing computer program for manufacturing the lighting apparatus.
  • WO 2010/128439 Al discloses an electroluminescent device comprising a layer system with a substrate and on top of the substrate a substrate electrode, a counter electrode and an electroluminescent layer stack with at least one organic electroluminescent layer arranged between the substrate electrode and the counter electrode. At least one optically transparent outcoupling body is provided on top of the substrate electrode to increase the outcoupling of light generated by the at least one organic electroluminescent layer, which at least partly covers the optical transparent outcoupling body.
  • a lighting apparatus for producing light comprising:
  • first electrode layer on the substrate and a second electrode layer for injecting charge carriers in a region between the first and second electrode layers
  • the light emission material is adapted to emit light, if the charge carriers are injected into the light emission material, wherein at least one of the first electrode layer and the second electrode layer is transparent to the light, in order to allow the light to leave the light emission material through the at least one of the first and second electrode layers, non-transparent reflecting elements between the substrate and the second electrode layer having reflecting surfaces enclosing an angle with the substrate being not 90 degrees.
  • the lighting apparatus comprises - in addition to the substrate, the first electrode layer, the second electrode layer, and the light emission material - non-transparent reflecting elements having reflecting surfaces enclosing an angle with the substrate being not 90 degrees, the reflection of the emitted light out of the light emission material through the first electrode layer and/or the second electrode layer can improved, thereby increasing the efficiency of coupling the light out of the lighting apparatus.
  • the substrate is preferentially a transparent substrate, which can be made of, for instance, glass or transparent plastics.
  • the light emission material is preferentially an organic material being adapted to emit light, if charge carriers are injected into the light emission material.
  • the light emission material comprises preferentially organic layers used by organic light emitting diodes (OLEDs).
  • the reflecting elements comprise preferentially metal.
  • the first electrode layer is preferentially an anode and the second electrode layer is preferentially a cathode.
  • the lighting apparatus is therefore preferentially an OLED, wherein the first and second electrode layers are an anode and a cathode, respectively, and the light emission material is formed by organic layers.
  • the first electrode layer is transparent to the light, in order to allow the light to leave the light emission material through the first electrode layer, wherein the reflecting surfaces enclose an angle with the substrate being smaller than 90 degrees.
  • the first electrode layer is, for instance, an indium tin oxide (ITO) layer for forming a transparent anode.
  • ITO indium tin oxide
  • the second electrode layer is preferentially a metal layer for providing a non-transparent cathode.
  • the second electrode layer can be transparent, or the first electrode layer can be non-transparent and the second electrode layer can be transparent. If only the second electrode layer is transparent, the reflecting surfaces preferentially enclose an angle with the substrate being larger than 90 degrees.
  • all reflecting surfaces of all of the non-transparent reflecting elements enclose an angle with the substrate being not smaller than 90 degrees or not larger than 90 degrees.
  • all reflecting surfaces of all of the non-transparent reflecting elements preferentially enclose an angle with the substrate being not larger than 90 degrees.
  • the second electrode layer is transparent and the first electrode layer is non-transparent, all reflecting surfaces of all of the non-transparent reflecting elements preferentially enclose an angle with the substrate being not smaller than 90 degrees. This further increases the efficiency of coupling light out of the lighting apparatus, if the first electrode layer is transparent and the second electrode layer is non- transparent, or if the first electrode layer is non-transparent and the second electrode layer is transparent, respectively.
  • the reflecting elements comprise curved reflecting surfaces which are sloped towards the substrate. This further increases the efficiency of coupling light out of the lighting apparatus, if the first electrode layer is transparent, in order to allow the light to leave the lighting apparatus through the first electrode layer.
  • reflecting elements with curved reflecting surfaces can be manufactured in a very efficient way by applying a first mask layer on, for example, the first electrode layer and by applying reflective material like metal onto the first mask layer and onto un-masked regions of the first electrode layer.
  • the reflecting elements can be provided on the first electrode layer, or they can be provided between the substrate and the first electrode layer.
  • parts, in particular, surfaces, of the reflecting elements facing the second electrode layer are covered with an insulating material.
  • surfaces of the reflecting elements enclosing an angle with the first electrode layer and the second electrode layer of 90 degrees can be covered with the insulating material.
  • the insulating material can reduce the likelihood of electrical short circuits within the lighting apparatus.
  • the reflecting elements are electrically connected to each other.
  • the electrically connected reflecting elements form a mesh, in particular, a honeycomb mesh.
  • the electrical connection of the reflecting elements can increase the conductivity of the first electrode layer, thereby increasing the number of charge carriers injected into the light emission material. This can lead to an increased intensity of the light provided by the lighting apparatus.
  • the reflecting elements are not electrically connected.
  • manufacturing method comprises: providing a substrate with a first electrode layer and with non- transparent reflecting elements having reflecting surfaces enclosing an angle with the substrate being not 90 degrees,
  • the first electrode layer is provided on the substrate and the reflecting elements are provided on the first electrode layer.
  • the reflecting elements are provided on the first electrode layer by applying a first mask layer for masking regions on the first electrode layer, by applying a reflecting material, which is reflective to the light produced by the lighting apparatus, at least on un-masked regions on the first electrode layer, and by removing the first mask layer.
  • the reflecting material comprises preferentially metal. It can be applied on the entire first mask layer and the first electrode layer, or it can be applied to the unmasked regions and edges of the first mask layer and not on the entire first mark layer.
  • the first mask layer is made of a first mask material being preferentially a resist.
  • a second mask layer is applied onto the reflecting material in regions in which the reflecting material is in contact with the first electrode layer, and parts of the reflecting material, which are not covered by the second mask layer, are removed. In particular, these parts are removed by using an etching procedure. The second mask layer is then preferentially removed with removing the first mask layer.
  • the first mask layer is applied by printing a first mask material.
  • the first mask material will have curved edges, which can finally lead to reflecting elements having curved reflecting surfaces.
  • the curved edges depend on the wetting behavior of the first mask material on the first electrode layer or on the substrate, respectively, if the reflecting elements are to be provided on the first electrode layer or on the substrate, respectively. This allows manufacturing the lighting apparatus such that the non- transparent reflecting elements have reflecting surfaces enclosing an angle with the substrate being smaller than 90 degrees in a relatively simple way.
  • the reflecting elements are provided on the substrate and the first electrode layer is provided on the reflecting elements.
  • the first electrode layer is preferentially an organic conductor layer provided on the reflecting elements.
  • manufacturing apparatus comprises:
  • a substrate provision unit for providing a substrate with a first electrode layer and with non-transparent reflecting elements having reflecting surfaces enclosing an angle with the substrate being not 90 degrees
  • a light emission layer application unit for applying a light emission layer on the first electrode layer and on the reflecting material
  • a second electrode layer application unit for applying a second electrode layer on the light emission layer.
  • a manufacturing computer program for manufacturing a lighting apparatus for producing light is presented, wherein the manufacturing computer program comprises program code means for causing a
  • Fig. 1 shows schematically and exemplarily an embodiment of a lighting apparatus for producing light
  • Fig. 2 shows schematically and exemplarily another embodiment of a lighting apparatus for producing light
  • Fig. 3 shows a flowchart exemplarily illustrating an embodiment of a manufacturing method for manufacturing a lighting apparatus for producing light
  • Figs. 4 to 11 show different layer structures produced during manufacturing the lighting apparatus
  • Fig. 12 shows schematically and exemplarily a manufacturing apparatus for manufacturing a lighting apparatus
  • Fig. 13 shows a top view on a substrate with a first electrode layer, contact surfaces for the first electrode layer and a second electrode layer, and non-transparent reflecting elements
  • Fig. 14 shows schematically and exemplarily the substrate after light emission material has been applied
  • Fig. 15 shows schematically and exemplarily the substrate after a second electrode layer has been applied.
  • Fig. 1 shows schematically and exemplarily an embodiment of a lighting apparatus for producing light.
  • the lighting apparatus 1 comprises a substrate 2 being, in this embodiment, a glass substrate.
  • a first electrode layer 3 being an anode layer is provided on the substrate 2 .
  • the anode layer 3 is an ITO layer.
  • the first electrode layer 3 is therefore transparent.
  • non-transparent reflecting elements 6 having reflecting surfaces 10 are arranged, wherein the reflecting surfaces 10 enclose an angle with the substrate 2 being not 90 degrees.
  • the non-transparent reflecting elements 6 comprise further surfaces 11 having an angle with the substrate 2 being substantially 90 degrees.
  • the reflecting elements 6 are metal elements.
  • the reflecting surfaces 10 are curved and sloped towards the substrate 2.
  • all curved reflecting surfaces 10 of all reflecting elements 6 are sloped towards the substrate 2 and enclose an angle with the substrate 2 being smaller than 90 degrees.
  • the lighting apparatus 1 further comprises light emission material 4 between the first electrode layer 3 and a second electrode layer 5.
  • the light emission material 4 comprises organic layers being adapted to emit light, if charge carriers are injected into the organic layers by using the first and second electrodes 3, 5.
  • the lighting apparatus 1 is therefore an OLED, wherein the first and second electrodes 3, 5 form the anode and the cathode, respectively, of the OLED, which are adapted to inject charge carriers into the organic layers 4.
  • the anode 3 and the cathode 5 are electrically connected via electrical connections 8 with a voltage source 9.
  • the surfaces 11 having an angle with the substrate 2 being substantially 90 degrees and further surfaces 12 of the reflecting elements 6 facing the cathode 5 are covered with an insulating material 7.
  • the insulating material 7 can be, for example, polyimide or a photoresist generally used in photolithography like an SU-8 photoresist or an acrylate resist. Since these surfaces 11, 12 of the reflecting elements 6 are covered with the insulating material, these surfaces may be not reflective anymore.
  • the remaining reflective surfaces 10 of the reflecting elements enclose an angle with the substrate being smaller than 90 degrees.
  • the light emission material 4 is provided on top of the insulating material 7 and on the first electrode layer 3.
  • the reflecting elements 6 are electrically connected to each other and form a mesh.
  • the mesh can be a honeycomb mesh or any other mesh. In another embodiment, the reflecting elements may not be electrically connected.
  • Fig. 1 and also the further figures are not drawn to scale.
  • the several shown elements can have different shapes and dimensions.
  • the shown layers can have different thicknesses.
  • Fig. 2 shows schematically and exemplarily a further embodiment of a lighting apparatus for producing light.
  • the lighting apparatus 101 shown in Fig. 2 comprises a substrate 2, reflecting elements 6, a first electrode layer 3, light emission material 4 including several organic layers, and a cathode layer 5.
  • the reflecting elements 6 are provided between the first electrode layer 3 and the substrate 2, and the surfaces 12 facing the cathode layer 5 are not covered by insulating material.
  • the first electrode layer 3 is not only located on the substrate 2, but also on top of the reflecting elements 6.
  • the light emission material 4 is provided on the first electrode layer 3 and the second electrode layer 5 finally covers the light emission material 4.
  • a substrate 2 being, in this embodiment, a glass substrate, covered by a first electrode layer 3 is provided as schematically and exemplarily shown in Fig. 4.
  • the first electrode layer 3 is preferentially an ITO layer and will form the anode of the lighting apparatus.
  • a first mask layer 13 is applied on the first electrode layer 3 for masking regions 14, in which the reflecting elements 6 should not be present.
  • a layer of resist is printed onto the first electrode layer 3.
  • the first mask layer 13 has spacings with a width of several millimeters.
  • the first mask material, of which the first mask layer is made comprises edges 15 being curved depending on the wetting behavior of the first mask material on the first electrode layer 3.
  • the first mask material is preferentially a resist ink.
  • a resulting layer structure is schematically and exemplarily shown in Fig. 5.
  • the first mask material can be a photoresist, which is generally used in photolithography.
  • a photoresist which is generally used in photolithography.
  • it can be a positive or negative photoresist like an SU-8 photoresist or an acrylate photoresist.
  • a reflecting material forming a reflecting layer 16 is applied at least on un-masked regions 17 between the masked regions 14 on the first electrode layer 3.
  • the reflecting material 16 is applied on the entire first mask layer 13 and the un-masked regions 17 of the first electrode layer 3.
  • the reflecting material is adapted to reflect the light produced by the final lighting apparatus and is preferentially metal.
  • the metal 16 conformably coats the first mask layer 13 as well as the uncoated first electrode layer 3.
  • a resulting layer structure is schematically and exemplarily shown in Fig. 6.
  • a second mask layer 18 is applied on the reflecting material 16 in regions in which the reflecting material 16 is contact with the first electrode layer 3.
  • the second mask layer 18 is provided in the regions 17, which are not mask by the first mask layer 13, and in regions surrounding these un-masked regions 17.
  • a resulting layer structure is schematically and exemplarily shown in Fig. 7.
  • the second mask layer 18 is a resist layer coated on top of the reflecting layer 16. The fractions of the reflecting layer 16, which are covered by the second mask layer 18, define the dimensions of the finally produced reflecting elements 6 within a plane being parallel to the substrate 2.
  • step 205 parts of the reflecting material 16, which are not covered by the second mask layer 18, are removed, thereby producing the reflecting elements 6.
  • an etching process is performed for etching the un-masked reflecting material 16 away from the layer structure.
  • the resulting layer structure is schematically and exemplarily shown in Fig. 8.
  • the first and second mask layers 13, 18 are removed by performing a stripping process, for example, by using solvents being adapted for solving the mask layers 13, 18 or by plasma etching.
  • the resulting layer structure is schematically and exemplarily shown in Fig. 9.
  • an electrically insulating material is applied on the remaining reflecting material 16 forming the reflecting elements. This coating of the reflecting elements by the insulating material reduces the likelihood of electrically short circuits in the final lighting apparatus.
  • a corresponding layer structure is schematically and exemplarily shown in Fig. 10.
  • a light emission layer 4 is applied on the first electrode layer 3 and the reflecting elements 6 with the insulating material 7. In particular, several organic layers forming the light emission layer are applied.
  • the resulting layer structure is schematically and exemplarily shown in Fig. 11.
  • a second electrode layer being, in this embodiment, a metal layer is provided on the light emission layer, wherein the resulting layer structure is shown in Fig. 1.
  • the first and second electrode layers 3 and 5 are then connected via electrical connections 8 with a voltage source 9 for forming the lighting apparatus in step 210.
  • the reflecting material of the reflecting layer is preferentially metal and also the second electrode layer comprises preferentially metal.
  • silver ink can be used for printing the reflecting layer and/or the second electrode layer, wherein in this case the reflecting layer and/or the second electrode layer, respectively, comprise silver.
  • the reflecting layer and/or the second electrode layer can be comprised of several metal layers like a chromium-aluminum-chromium layer structure or like a molybdenum-aluminum-molybdenum layer structure. These different metal layers can be applied by performing a vapor deposition.
  • the second mask material can be a photoresist generally used in the field of photolithography like an SU-8 photoresist or an acrylate photoresist.
  • Fig. 12 shows schematically and exemplarily an embodiment of a manufacturing apparatus for manufacturing a lighting apparatus for producing light, which is adapted to perform the manufacturing method described above with reference to Fig. 3.
  • the manufacturing apparatus 300 comprises a providing unit 301 for providing a substrate 2 with a first electrode layer 3.
  • the providing unit 301 can be a storage unit, which provides already prepared substrates with first electrode layers, or the providing unit 301 can be adapted to apply the first electrode layer, which is preferentially an ITO layer, on the substrate for providing the substrate with the first electrode layer.
  • a first mask layer providing unit 302 applies then the first mask layer 13 on the regions 14 on the first electrode layer 3 for masking these regions.
  • the reflecting material 16 is then applied by a reflecting material application unit 303.
  • a second mask layer application unit 304 applies the second mask layer 18 onto the reflecting material 16 in regions in which the reflecting material 16 is in contact with the first electrode layer 3.
  • a reflecting material removing unit 305 Parts of the reflecting material 16, which are not covered by the second mask layer 18, are removed by a reflecting material removing unit 305.
  • a mask layer removing unit 306 then removes the first and second mask layers 13, 18.
  • An insulating material application unit 307 applies insulating material on the remaining parts of the reflecting material forming the reflecting elements, and a light emission layer application unit 308 applies the light emission material on the first electrode layer and on the reflecting material.
  • the light emission layer application unit applies organic layers, which are adapted to emit light if charge carriers are injected, onto the first electrode layer 3 and the reflecting material.
  • a second electrode layer application unit 309 applies the second electrode layer 5 onto the light emission layer, and an electrical connection unit 310 is used for electrically connecting the first and second electrode layers with a voltage source.
  • the respective layer structure can, for example, be moved from one unit to another unit by using a conveying system like a conveyer belt (not shown in Fig. 12).
  • the substrate 2 with the first electrode layer 3 provided in step 201 can comprise further characteristics, which are not shown in Fig. 4 for clarity reasons.
  • it can comprise a contact surface for the first electrode layer and a further contact surface for the second electrode layer.
  • it can comprise an electrical insulation between the first electrode layer being, in this embodiment, an anode layer and the contact surface of the second electrode layer.
  • Fig. 13 shows schematically and exemplarily a corresponding layer structure, before the light emission material with the organic layers and the second electrode layer being, in this embodiment, a cathode layer are applied.
  • a substrate has been totally coated with the conductive material forming the first electrode layer.
  • a first region 22 is metalized for providing a first contact surface for the first electrode layer and a second region 20 is metalized for forming a second contact surface for the second electrode layer.
  • the first electrode 3 is formed within the region defined by the insulating lines 21, which may be provided by spacings in the conductive material provided on the substrate.
  • the reflecting elements 6 are electrically connected and form a mesh.
  • Fig. 14 shows schematically and exemplarily a top view of the layer structure after the light emission material 4 has been applied.
  • the light emission material 4 is, in this embodiment, comprised of a stack of organic layers, which emit light, if charge carriers are injected. In this example, the light emission material 4 extends into the regions defined by the contact surfaces 20, 22.
  • Fig. 15 shows schematically and exemplarily a top view on the layer structure, after the second electrode layer 5, which is, in this embodiment, a cathode layer, has been applied.
  • the second electrode layer 5 In the region defined by the contact surface 20 the second electrode layer 5 has an extension being larger than the extension of the light emission material 4 and is electrically connected to this contact surface. In the region defined by the other contact surface 22 the extension of the second electrode layer 5 is smaller than the extension of the light emission material 4.
  • the reflecting material 16 can be applied to the un-masked regions 17 and edges of the first mask layer 13 and not on the entire first mask layer 13.
  • the application of a second mask layer onto the reflecting material in regions in which the reflecting material is in contact with the first electrode layer and a removement of parts of the reflecting material, which are not covered by the second mask layer are not necessary.
  • metal paste can be printed into open ISO structures formed by the first mask layer, where metal structures forming the reflecting elements should remain.
  • steps 204 and 205 can be omitted.
  • step 201 in another embodiment in step 201 only the substrate can be provided, wherein then the reflecting elements can be formed on the substrate, for instance, by performing steps 202 to 206. Then, the first electrode layer, the light emission material and the second electrode layer can be applied on the substrate with the reflecting elements for forming, for example, the lighting apparatus schematically and exemplarily shown in Fig. 2.
  • metal structures forming the reflecting elements can be manufactured onto the substrate, wherein later an anode layer can be coated onto the metal structures, for example, by coating a conductive organic conductor.
  • an insulator on the reflecting elements is not required.
  • the first electrode layer is a transparent anode layer and the second electrode layer is a non-transparent cathode layer
  • both layers can be transparent or only the cathode layer can be transparent.
  • the reflecting surfaces of the reflecting elements preferentially enclose an angle with a substrate being larger than 90 degrees such that light generated by the light emission material is directly reflected to the cathode layer.
  • the reflecting surfaces of the reflecting elements preferentially enclose an angle with the substrate being smaller than 90 degrees such that light generated by the light emission material is directly reflected to the transparent anode layer.
  • the reflecting elements can be regarded as being micro mirrors for deflecting light from being in the respective OLED plane towards the substrate, in order to extract more of the generated light from the OLED.
  • the manufacturing process is preferentially based on depositing a metal layer onto printed insulator patterns formed by the first mask layer and removing the insulator pattern afterwards, in order to leave metal structures forming the reflecting elements behind.
  • OLEDs In known OLEDs most of the generated light cannot leave the lighting apparatus. One of the reasons is a difference in refractive indices between the organic layers and the surrounding material. This leads to total reflections at the interfaces between the organic layers and the surrounding material and therefore to waveguide modes in different layers of a typical OLED device.
  • a second reason for light trapping is the physical nature of light generation in an OLED. Organic molecules are randomly oriented in the organic layers. When these organic molecules are excited by charge carrier injection, the organic molecules relax by emission of light. As the orientation of the organic molecules with respect to the substrate surface is random, also the light emission by the organic molecules is random. This means that a significant amount of light is emitted in a plane parallel to the substrate surface. In known OLEDs these light modes cannot leave the lighting apparatus, but are trapped in the OLED plane and can get re-absorbed by the organic molecules, which then decay non- radiatively.
  • the reflecting elements are preferentially adapted to deflect the light in the plane of the organic stack towards the substrate surface by reflective surfaces of the reflecting elements having an angle not being 90 degrees.
  • the reflecting elements can be regarded as being pillars, which are
  • the reflecting elements can fulfill two functions: they can act as shunt lines to increase the electrical conductivity of, for example, the anode layer and they can deflect the in plane light modes and guide them towards the substrate.
  • the reflecting elements can be individual pillars, which are not electrically connected. In this case, the reflecting elements function mainly as deflection elements.
  • a single unit or device may fulfill the functions of several items recited in the claims.
  • the mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
  • Manufacturing steps performed by one or several units or devices can be performed by any other number of units or devices.
  • the application of certain layers like the application of the first and second mask layers can be performed by a single unit or by any other number of different units.
  • the control of the manufacturing apparatus in accordance with the manufacturing method can be implemented as program code means of a computer program and/or as dedicated hardware.
  • a computer program may be stored/distributed on a suitable medium, such as an optical storage medium or a solid-state medium, supplied together with or as part of other hardware, but may also be distributed in other forms, such as via the Internet or other wired or wireless telecommunication systems.
  • a suitable medium such as an optical storage medium or a solid-state medium, supplied together with or as part of other hardware, but may also be distributed in other forms, such as via the Internet or other wired or wireless telecommunication systems.
  • the invention relates to a lighting apparatus for producing light, in particular, to an organic light emitting diode.
  • the lighting apparatus comprises a substrate, a first electrode layer on the substrate and a second electrode layer for injecting charge carriers in light emission material located between the electrode layers. At least one of the first electrode layer and the second electrode layer is transparent for allowing emitted light to leave the light emission material.
  • Non-transparent reflecting elements are present between the substrate and the second electrode layer having reflecting surfaces enclosing an angle with the substrate being not 90 degrees. These non-transparent reflecting elements reflect the emitted light out of the lighting apparatus, thereby increasing the efficiency of coupling the light out of the lighting apparatus.

Abstract

The invention relates to a lighting apparatus (1) for producing light, in particular, to an organic light emitting diode. The lighting apparatus comprises a substrate (2), a first electrode layer (3) on the substrate and a second electrode layer (5) for injecting charge carriers in light emission material (4) located between the electrode layers. At least one of the first electrode layer and the second electrode layer is transparent for allowing emitted light to leave the light emission material. Non-transparent reflecting elements (6) are present between the substrate and the second electrode layer having reflecting surfaces (10) enclosing an angle with the substrate being not 90 degrees. These non-transparent reflecting elements reflect the emitted light out of the lighting apparatus, thereby increasing the efficiency of coupling the light out of the lighting apparatus.

Description

Lighting Apparatus And Manufacturing Method For Manufacturing The Lighting Apparatus
FIELD OF THE INVENTION
The invention relates to a lighting apparatus for producing light. The invention relates further to a manufacturing method, a manufacturing apparatus and a manufacturing computer program for manufacturing the lighting apparatus. BACKGROUND OF THE INVENTION
WO 2010/128439 Al discloses an electroluminescent device comprising a layer system with a substrate and on top of the substrate a substrate electrode, a counter electrode and an electroluminescent layer stack with at least one organic electroluminescent layer arranged between the substrate electrode and the counter electrode. At least one optically transparent outcoupling body is provided on top of the substrate electrode to increase the outcoupling of light generated by the at least one organic electroluminescent layer, which at least partly covers the optical transparent outcoupling body.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a lighting apparatus for producing light, wherein the outcoupling of the light out of the lighting apparatus can be further improved. It is a further object of the present invention to provide a manufacturing method, a manufacturing apparatus and a manufacturing computer program for
manufacturing the lighting apparatus.
In a first aspect of the present invention a lighting apparatus for producing light is presented, wherein the lighting apparatus comprises:
a substrate,
a first electrode layer on the substrate and a second electrode layer for injecting charge carriers in a region between the first and second electrode layers,
- a light emission material between the first and second electrode layers, wherein the light emission material is adapted to emit light, if the charge carriers are injected into the light emission material, wherein at least one of the first electrode layer and the second electrode layer is transparent to the light, in order to allow the light to leave the light emission material through the at least one of the first and second electrode layers, non-transparent reflecting elements between the substrate and the second electrode layer having reflecting surfaces enclosing an angle with the substrate being not 90 degrees.
Since the lighting apparatus comprises - in addition to the substrate, the first electrode layer, the second electrode layer, and the light emission material - non-transparent reflecting elements having reflecting surfaces enclosing an angle with the substrate being not 90 degrees, the reflection of the emitted light out of the light emission material through the first electrode layer and/or the second electrode layer can improved, thereby increasing the efficiency of coupling the light out of the lighting apparatus.
The substrate is preferentially a transparent substrate, which can be made of, for instance, glass or transparent plastics. The light emission material is preferentially an organic material being adapted to emit light, if charge carriers are injected into the light emission material. The light emission material comprises preferentially organic layers used by organic light emitting diodes (OLEDs). The reflecting elements comprise preferentially metal. The first electrode layer is preferentially an anode and the second electrode layer is preferentially a cathode. The lighting apparatus is therefore preferentially an OLED, wherein the first and second electrode layers are an anode and a cathode, respectively, and the light emission material is formed by organic layers.
It is preferred that the first electrode layer is transparent to the light, in order to allow the light to leave the light emission material through the first electrode layer, wherein the reflecting surfaces enclose an angle with the substrate being smaller than 90 degrees. This further increases the efficiency of coupling light out of the lighting apparatus, if the first electrode layer is transparent. The first electrode layer is, for instance, an indium tin oxide (ITO) layer for forming a transparent anode. The second electrode layer is preferentially a metal layer for providing a non-transparent cathode. In other embodiments, also the second electrode layer can be transparent, or the first electrode layer can be non-transparent and the second electrode layer can be transparent. If only the second electrode layer is transparent, the reflecting surfaces preferentially enclose an angle with the substrate being larger than 90 degrees.
Preferentially, all reflecting surfaces of all of the non-transparent reflecting elements enclose an angle with the substrate being not smaller than 90 degrees or not larger than 90 degrees. In particular, if the first electrode layer is transparent and the second electrode layer is non-transparent, all reflecting surfaces of all of the non-transparent reflecting elements preferentially enclose an angle with the substrate being not larger than 90 degrees. If, in another embodiment, the second electrode layer is transparent and the first electrode layer is non-transparent, all reflecting surfaces of all of the non-transparent reflecting elements preferentially enclose an angle with the substrate being not smaller than 90 degrees. This further increases the efficiency of coupling light out of the lighting apparatus, if the first electrode layer is transparent and the second electrode layer is non- transparent, or if the first electrode layer is non-transparent and the second electrode layer is transparent, respectively.
It is further preferred that the reflecting elements comprise curved reflecting surfaces which are sloped towards the substrate. This further increases the efficiency of coupling light out of the lighting apparatus, if the first electrode layer is transparent, in order to allow the light to leave the lighting apparatus through the first electrode layer. Moreover, reflecting elements with curved reflecting surfaces can be manufactured in a very efficient way by applying a first mask layer on, for example, the first electrode layer and by applying reflective material like metal onto the first mask layer and onto un-masked regions of the first electrode layer.
The reflecting elements can be provided on the first electrode layer, or they can be provided between the substrate and the first electrode layer.
Preferentially, parts, in particular, surfaces, of the reflecting elements facing the second electrode layer are covered with an insulating material. Also surfaces of the reflecting elements enclosing an angle with the first electrode layer and the second electrode layer of 90 degrees can be covered with the insulating material. The insulating material can reduce the likelihood of electrical short circuits within the lighting apparatus.
It is also preferred that the reflecting elements are electrically connected to each other. In an embodiment, the electrically connected reflecting elements form a mesh, in particular, a honeycomb mesh. The electrical connection of the reflecting elements can increase the conductivity of the first electrode layer, thereby increasing the number of charge carriers injected into the light emission material. This can lead to an increased intensity of the light provided by the lighting apparatus. In another embodiment, the reflecting elements are not electrically connected.
In a further aspect of the present invention a manufacturing method for manufacturing a lighting apparatus for producing light is presented, wherein the
manufacturing method comprises: providing a substrate with a first electrode layer and with non- transparent reflecting elements having reflecting surfaces enclosing an angle with the substrate being not 90 degrees,
applying a light emission layer on the first electrode layer and on the reflecting material,
applying a second electrode layer on the light emission layer.
In a preferred embodiment, the first electrode layer is provided on the substrate and the reflecting elements are provided on the first electrode layer.
It is further preferred that the reflecting elements are provided on the first electrode layer by applying a first mask layer for masking regions on the first electrode layer, by applying a reflecting material, which is reflective to the light produced by the lighting apparatus, at least on un-masked regions on the first electrode layer, and by removing the first mask layer. The reflecting material comprises preferentially metal. It can be applied on the entire first mask layer and the first electrode layer, or it can be applied to the unmasked regions and edges of the first mask layer and not on the entire first mark layer. The first mask layer is made of a first mask material being preferentially a resist.
In an embodiment, before removing the first mask layer, a second mask layer is applied onto the reflecting material in regions in which the reflecting material is in contact with the first electrode layer, and parts of the reflecting material, which are not covered by the second mask layer, are removed. In particular, these parts are removed by using an etching procedure. The second mask layer is then preferentially removed with removing the first mask layer.
In a preferred embodiment, the first mask layer is applied by printing a first mask material. The first mask material will have curved edges, which can finally lead to reflecting elements having curved reflecting surfaces. The curved edges depend on the wetting behavior of the first mask material on the first electrode layer or on the substrate, respectively, if the reflecting elements are to be provided on the first electrode layer or on the substrate, respectively. This allows manufacturing the lighting apparatus such that the non- transparent reflecting elements have reflecting surfaces enclosing an angle with the substrate being smaller than 90 degrees in a relatively simple way.
It is further preferred that an insulating material is applied on the reflecting elements. In an embodiment, the reflecting elements are provided on the substrate and the first electrode layer is provided on the reflecting elements. In this case, the first electrode layer is preferentially an organic conductor layer provided on the reflecting elements.
In a further aspect of the present invention a manufacturing apparatus for manufacturing a lighting apparatus for producing light is presented, wherein the
manufacturing apparatus comprises:
a substrate provision unit for providing a substrate with a first electrode layer and with non-transparent reflecting elements having reflecting surfaces enclosing an angle with the substrate being not 90 degrees,
a light emission layer application unit for applying a light emission layer on the first electrode layer and on the reflecting material,
a second electrode layer application unit for applying a second electrode layer on the light emission layer.
In a further aspect of the present invention a manufacturing computer program for manufacturing a lighting apparatus for producing light is presented, wherein the manufacturing computer program comprises program code means for causing a
manufacturing apparatus as defined in claim 14 to carry out the steps of the manufacturing method as defined in claim 8, when the manufacturing computer program is run on a computer controlling the manufacturing apparatus.
It shall be understood that the lighting apparatus of claim 1 , the manufacturing method of claim 8, the manufacturing apparatus of claim 14 and the manufacturing computer program of claim 15 have similar and/or identical preferred embodiments, in particular, as defined in the dependent claims.
It shall be understood that a preferred embodiment of the invention can also be any combination of the dependent claims with the respective independent claim.
These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following drawings:
Fig. 1 shows schematically and exemplarily an embodiment of a lighting apparatus for producing light,
Fig. 2 shows schematically and exemplarily another embodiment of a lighting apparatus for producing light, Fig. 3 shows a flowchart exemplarily illustrating an embodiment of a manufacturing method for manufacturing a lighting apparatus for producing light,
Figs. 4 to 11 show different layer structures produced during manufacturing the lighting apparatus,
Fig. 12 shows schematically and exemplarily a manufacturing apparatus for manufacturing a lighting apparatus,
Fig. 13 shows a top view on a substrate with a first electrode layer, contact surfaces for the first electrode layer and a second electrode layer, and non-transparent reflecting elements,
Fig. 14 shows schematically and exemplarily the substrate after light emission material has been applied, and
Fig. 15 shows schematically and exemplarily the substrate after a second electrode layer has been applied. DETAILED DESCRIPTION OF EMBODIMENTS
Fig. 1 shows schematically and exemplarily an embodiment of a lighting apparatus for producing light. The lighting apparatus 1 comprises a substrate 2 being, in this embodiment, a glass substrate. On the substrate 2 a first electrode layer 3 being an anode layer is provided. In this embodiment, the anode layer 3 is an ITO layer. The first electrode layer 3 is therefore transparent.
On the first electrode layer 3 non-transparent reflecting elements 6 having reflecting surfaces 10 are arranged, wherein the reflecting surfaces 10 enclose an angle with the substrate 2 being not 90 degrees. The non-transparent reflecting elements 6 comprise further surfaces 11 having an angle with the substrate 2 being substantially 90 degrees. The reflecting elements 6 are metal elements. In this embodiment, the reflecting surfaces 10 are curved and sloped towards the substrate 2. In particular, all curved reflecting surfaces 10 of all reflecting elements 6 are sloped towards the substrate 2 and enclose an angle with the substrate 2 being smaller than 90 degrees.
The lighting apparatus 1 further comprises light emission material 4 between the first electrode layer 3 and a second electrode layer 5. The light emission material 4 comprises organic layers being adapted to emit light, if charge carriers are injected into the organic layers by using the first and second electrodes 3, 5. The lighting apparatus 1 is therefore an OLED, wherein the first and second electrodes 3, 5 form the anode and the cathode, respectively, of the OLED, which are adapted to inject charge carriers into the organic layers 4. The anode 3 and the cathode 5 are electrically connected via electrical connections 8 with a voltage source 9.
The surfaces 11 having an angle with the substrate 2 being substantially 90 degrees and further surfaces 12 of the reflecting elements 6 facing the cathode 5 are covered with an insulating material 7. The insulating material 7 can be, for example, polyimide or a photoresist generally used in photolithography like an SU-8 photoresist or an acrylate resist. Since these surfaces 11, 12 of the reflecting elements 6 are covered with the insulating material, these surfaces may be not reflective anymore. The remaining reflective surfaces 10 of the reflecting elements enclose an angle with the substrate being smaller than 90 degrees.
The light emission material 4 is provided on top of the insulating material 7 and on the first electrode layer 3.
The reflecting elements 6 are electrically connected to each other and form a mesh. The mesh can be a honeycomb mesh or any other mesh. In another embodiment, the reflecting elements may not be electrically connected.
It should be noted that Fig. 1 and also the further figures are not drawn to scale. The several shown elements can have different shapes and dimensions. In particular, the shown layers can have different thicknesses.
Fig. 2 shows schematically and exemplarily a further embodiment of a lighting apparatus for producing light. Also the lighting apparatus 101 shown in Fig. 2 comprises a substrate 2, reflecting elements 6, a first electrode layer 3, light emission material 4 including several organic layers, and a cathode layer 5. However, in this embodiment, the reflecting elements 6 are provided between the first electrode layer 3 and the substrate 2, and the surfaces 12 facing the cathode layer 5 are not covered by insulating material. In particular, the first electrode layer 3 is not only located on the substrate 2, but also on top of the reflecting elements 6. The light emission material 4 is provided on the first electrode layer 3 and the second electrode layer 5 finally covers the light emission material 4.
In the following an embodiment of a manufacturing method for manufacturing a lighting apparatus for producing light will exemplarily be described with reference to a flowchart shown in Fig. 3.
In step 201, a substrate 2 being, in this embodiment, a glass substrate, covered by a first electrode layer 3 is provided as schematically and exemplarily shown in Fig. 4. The first electrode layer 3 is preferentially an ITO layer and will form the anode of the lighting apparatus. In step 202, a first mask layer 13 is applied on the first electrode layer 3 for masking regions 14, in which the reflecting elements 6 should not be present. In particular, a layer of resist is printed onto the first electrode layer 3. The first mask layer 13 has spacings with a width of several millimeters. The first mask material, of which the first mask layer is made, comprises edges 15 being curved depending on the wetting behavior of the first mask material on the first electrode layer 3. The first mask material is preferentially a resist ink. A resulting layer structure is schematically and exemplarily shown in Fig. 5.
The first mask material can be a photoresist, which is generally used in photolithography. For instance, it can be a positive or negative photoresist like an SU-8 photoresist or an acrylate photoresist.
In step 203, a reflecting material forming a reflecting layer 16 is applied at least on un-masked regions 17 between the masked regions 14 on the first electrode layer 3. In this embodiment, the reflecting material 16 is applied on the entire first mask layer 13 and the un-masked regions 17 of the first electrode layer 3. The reflecting material is adapted to reflect the light produced by the final lighting apparatus and is preferentially metal. In this embodiment, the metal 16 conformably coats the first mask layer 13 as well as the uncoated first electrode layer 3. A resulting layer structure is schematically and exemplarily shown in Fig. 6.
In step 204, a second mask layer 18 is applied on the reflecting material 16 in regions in which the reflecting material 16 is contact with the first electrode layer 3. In particular, the second mask layer 18 is provided in the regions 17, which are not mask by the first mask layer 13, and in regions surrounding these un-masked regions 17. A resulting layer structure is schematically and exemplarily shown in Fig. 7. Also the second mask layer 18 is a resist layer coated on top of the reflecting layer 16. The fractions of the reflecting layer 16, which are covered by the second mask layer 18, define the dimensions of the finally produced reflecting elements 6 within a plane being parallel to the substrate 2.
In step 205, parts of the reflecting material 16, which are not covered by the second mask layer 18, are removed, thereby producing the reflecting elements 6. In particular, an etching process is performed for etching the un-masked reflecting material 16 away from the layer structure. The resulting layer structure is schematically and exemplarily shown in Fig. 8.
In step 206, the first and second mask layers 13, 18 are removed by performing a stripping process, for example, by using solvents being adapted for solving the mask layers 13, 18 or by plasma etching. The resulting layer structure is schematically and exemplarily shown in Fig. 9. After the mask layers, which can be made of an ISO resist, have been removed, in step 207 an electrically insulating material is applied on the remaining reflecting material 16 forming the reflecting elements. This coating of the reflecting elements by the insulating material reduces the likelihood of electrically short circuits in the final lighting apparatus. A corresponding layer structure is schematically and exemplarily shown in Fig. 10.
In step 208, a light emission layer 4 is applied on the first electrode layer 3 and the reflecting elements 6 with the insulating material 7. In particular, several organic layers forming the light emission layer are applied. The resulting layer structure is schematically and exemplarily shown in Fig. 11. In step 209, a second electrode layer being, in this embodiment, a metal layer is provided on the light emission layer, wherein the resulting layer structure is shown in Fig. 1. The first and second electrode layers 3 and 5 are then connected via electrical connections 8 with a voltage source 9 for forming the lighting apparatus in step 210.
The reflecting material of the reflecting layer is preferentially metal and also the second electrode layer comprises preferentially metal. For instance, silver ink can be used for printing the reflecting layer and/or the second electrode layer, wherein in this case the reflecting layer and/or the second electrode layer, respectively, comprise silver. However, also other metals can be used. For instance, the reflecting layer and/or the second electrode layer can be comprised of several metal layers like a chromium-aluminum-chromium layer structure or like a molybdenum-aluminum-molybdenum layer structure. These different metal layers can be applied by performing a vapor deposition. The second mask material can be a photoresist generally used in the field of photolithography like an SU-8 photoresist or an acrylate photoresist.
Fig. 12 shows schematically and exemplarily an embodiment of a manufacturing apparatus for manufacturing a lighting apparatus for producing light, which is adapted to perform the manufacturing method described above with reference to Fig. 3.
The manufacturing apparatus 300 comprises a providing unit 301 for providing a substrate 2 with a first electrode layer 3. The providing unit 301 can be a storage unit, which provides already prepared substrates with first electrode layers, or the providing unit 301 can be adapted to apply the first electrode layer, which is preferentially an ITO layer, on the substrate for providing the substrate with the first electrode layer. A first mask layer providing unit 302 applies then the first mask layer 13 on the regions 14 on the first electrode layer 3 for masking these regions. The reflecting material 16 is then applied by a reflecting material application unit 303. A second mask layer application unit 304 applies the second mask layer 18 onto the reflecting material 16 in regions in which the reflecting material 16 is in contact with the first electrode layer 3. Parts of the reflecting material 16, which are not covered by the second mask layer 18, are removed by a reflecting material removing unit 305. A mask layer removing unit 306 then removes the first and second mask layers 13, 18. An insulating material application unit 307 applies insulating material on the remaining parts of the reflecting material forming the reflecting elements, and a light emission layer application unit 308 applies the light emission material on the first electrode layer and on the reflecting material. In particular, the light emission layer application unit applies organic layers, which are adapted to emit light if charge carriers are injected, onto the first electrode layer 3 and the reflecting material. A second electrode layer application unit 309 applies the second electrode layer 5 onto the light emission layer, and an electrical connection unit 310 is used for electrically connecting the first and second electrode layers with a voltage source. The respective layer structure can, for example, be moved from one unit to another unit by using a conveying system like a conveyer belt (not shown in Fig. 12).
The substrate 2 with the first electrode layer 3 provided in step 201 can comprise further characteristics, which are not shown in Fig. 4 for clarity reasons. For example, it can comprise a contact surface for the first electrode layer and a further contact surface for the second electrode layer. Moreover, it can comprise an electrical insulation between the first electrode layer being, in this embodiment, an anode layer and the contact surface of the second electrode layer. Fig. 13 shows schematically and exemplarily a corresponding layer structure, before the light emission material with the organic layers and the second electrode layer being, in this embodiment, a cathode layer are applied.
As can been seen in Fig. 13, which shows a top view, a substrate has been totally coated with the conductive material forming the first electrode layer. On this conductive material, a first region 22 is metalized for providing a first contact surface for the first electrode layer and a second region 20 is metalized for forming a second contact surface for the second electrode layer. The first electrode 3 is formed within the region defined by the insulating lines 21, which may be provided by spacings in the conductive material provided on the substrate. The reflecting elements 6 are electrically connected and form a mesh.
Fig. 14 shows schematically and exemplarily a top view of the layer structure after the light emission material 4 has been applied. The light emission material 4 is, in this embodiment, comprised of a stack of organic layers, which emit light, if charge carriers are injected. In this example, the light emission material 4 extends into the regions defined by the contact surfaces 20, 22.
Fig. 15 shows schematically and exemplarily a top view on the layer structure, after the second electrode layer 5, which is, in this embodiment, a cathode layer, has been applied. In the region defined by the contact surface 20 the second electrode layer 5 has an extension being larger than the extension of the light emission material 4 and is electrically connected to this contact surface. In the region defined by the other contact surface 22 the extension of the second electrode layer 5 is smaller than the extension of the light emission material 4.
Although in the above described manufacturing method in step 203 the reflecting material has been applied to the entire first mask layer, in another embodiment the reflecting material 16 can be applied to the un-masked regions 17 and edges of the first mask layer 13 and not on the entire first mask layer 13. In this case, the application of a second mask layer onto the reflecting material in regions in which the reflecting material is in contact with the first electrode layer and a removement of parts of the reflecting material, which are not covered by the second mask layer, are not necessary. In particular, instead of full area metal coating and afterwards etching of excess metal, metal paste can be printed into open ISO structures formed by the first mask layer, where metal structures forming the reflecting elements should remain. In this embodiment, steps 204 and 205 can be omitted.
Although in the embodiment of the manufacturing method described above with reference to Fig. 3 in step 201 a substrate with a first electrode layer is provided, in another embodiment in step 201 only the substrate can be provided, wherein then the reflecting elements can be formed on the substrate, for instance, by performing steps 202 to 206. Then, the first electrode layer, the light emission material and the second electrode layer can be applied on the substrate with the reflecting elements for forming, for example, the lighting apparatus schematically and exemplarily shown in Fig. 2. Thus, in an embodiment metal structures forming the reflecting elements can be manufactured onto the substrate, wherein later an anode layer can be coated onto the metal structures, for example, by coating a conductive organic conductor. In this embodiment, an insulator on the reflecting elements is not required.
Although in the above described embodiment the first electrode layer is a transparent anode layer and the second electrode layer is a non-transparent cathode layer, in other embodiments both layers can be transparent or only the cathode layer can be transparent. If only the cathode layer is transparent, the reflecting surfaces of the reflecting elements preferentially enclose an angle with a substrate being larger than 90 degrees such that light generated by the light emission material is directly reflected to the cathode layer. If only the anode layer is transparent, the reflecting surfaces of the reflecting elements preferentially enclose an angle with the substrate being smaller than 90 degrees such that light generated by the light emission material is directly reflected to the transparent anode layer.
The reflecting elements can be regarded as being micro mirrors for deflecting light from being in the respective OLED plane towards the substrate, in order to extract more of the generated light from the OLED. The manufacturing process is preferentially based on depositing a metal layer onto printed insulator patterns formed by the first mask layer and removing the insulator pattern afterwards, in order to leave metal structures forming the reflecting elements behind.
In known OLEDs most of the generated light cannot leave the lighting apparatus. One of the reasons is a difference in refractive indices between the organic layers and the surrounding material. This leads to total reflections at the interfaces between the organic layers and the surrounding material and therefore to waveguide modes in different layers of a typical OLED device. A second reason for light trapping is the physical nature of light generation in an OLED. Organic molecules are randomly oriented in the organic layers. When these organic molecules are excited by charge carrier injection, the organic molecules relax by emission of light. As the orientation of the organic molecules with respect to the substrate surface is random, also the light emission by the organic molecules is random. This means that a significant amount of light is emitted in a plane parallel to the substrate surface. In known OLEDs these light modes cannot leave the lighting apparatus, but are trapped in the OLED plane and can get re-absorbed by the organic molecules, which then decay non- radiatively.
In order to overcome these drawbacks, the reflecting elements are preferentially adapted to deflect the light in the plane of the organic stack towards the substrate surface by reflective surfaces of the reflecting elements having an angle not being 90 degrees.
The reflecting elements can be regarded as being pillars, which are
preferentially electrically connected. These electrically connected pillars can be regarded as being shunt structures, wherein shunt lines of the shunt structures can increase the electrical conductivity of, for example, the anode layer. Thus, the reflecting elements can fulfill two functions: they can act as shunt lines to increase the electrical conductivity of, for example, the anode layer and they can deflect the in plane light modes and guide them towards the substrate. In other embodiments, the reflecting elements can be individual pillars, which are not electrically connected. In this case, the reflecting elements function mainly as deflection elements. Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims.
In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality.
A single unit or device may fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
Manufacturing steps performed by one or several units or devices can be performed by any other number of units or devices. For example, the application of certain layers like the application of the first and second mask layers can be performed by a single unit or by any other number of different units. The control of the manufacturing apparatus in accordance with the manufacturing method can be implemented as program code means of a computer program and/or as dedicated hardware.
A computer program may be stored/distributed on a suitable medium, such as an optical storage medium or a solid-state medium, supplied together with or as part of other hardware, but may also be distributed in other forms, such as via the Internet or other wired or wireless telecommunication systems.
Any reference signs in the claims should not be construed as limiting the scope.
The invention relates to a lighting apparatus for producing light, in particular, to an organic light emitting diode. The lighting apparatus comprises a substrate, a first electrode layer on the substrate and a second electrode layer for injecting charge carriers in light emission material located between the electrode layers. At least one of the first electrode layer and the second electrode layer is transparent for allowing emitted light to leave the light emission material. Non-transparent reflecting elements are present between the substrate and the second electrode layer having reflecting surfaces enclosing an angle with the substrate being not 90 degrees. These non-transparent reflecting elements reflect the emitted light out of the lighting apparatus, thereby increasing the efficiency of coupling the light out of the lighting apparatus.

Claims

CLAIMS:
1. A lighting apparatus for producing light, the lighting apparatus (1; 101) comprising:
a substrate (2),
a first electrode layer (3) on the substrate (2) and a second electrode layer (5) for injecting charge carriers in a region between the first and second electrode layers (3, 5),
a light emission material (4) between the first and second electrode layers (3, 5), wherein the light emission material (4) is adapted to emit light, if the charge carriers are injected into the light emission material (4), wherein at least one of the first electrode layer (3) and the second electrode layer (5) is transparent to the light, in order to allow the light to leave the light emission material through the at least one of the first and second electrode layers (3, 5),
non-transparent reflecting elements (6) between the substrate and the second electrode layer having reflecting surfaces (10) enclosing an angle with the substrate (2) being not 90 degrees.
2. The lighting apparatus as defined in claim 1, wherein the first electrode layer
(3) is transparent to the light, in order to allow the light to leave the light emission material
(4) through the first electrode layer (3), and wherein the reflecting surfaces (10) enclose an angle with the substrate being smaller than 90 degrees.
3. The lighting apparatus as defined in claim 1, wherein the reflecting elements (6) comprise curved reflecting surfaces (10) which are sloped towards the substrate (2).
4. The lighting apparatus as defined in claim 1, wherein the reflecting elements
(6) are provided on the first electrode layer (3).
5. The lighting apparatus as defined in claim 1, wherein the reflecting elements
(6) are provided between the substrate (2) and the first electrode layer (3).
6. The lighting apparatus as defined in claim 1, wherein parts of the reflecting elements (6) facing the second electrode layer (5) are covered with an insulating material (7).
7. The lighting apparatus as defined in claim 1, wherein the reflecting elements
(6) are electrically connected to each other.
8. A manufacturing method for manufacturing a lighting apparatus for producing light, the manufacturing method comprising:
- providing a substrate (2) with a first electrode layer (3) and with non- transparent reflecting elements having reflecting surfaces enclosing an angle with the substrate being not 90 degrees,
applying a light emission layer on the first electrode layer and on the reflecting material,
- applying a second electrode layer on the light emission layer.
9. The manufacturing method as defined in claim 8, wherein the first electrode layer is provided on the substrate and the reflecting elements are provided on the first electrode layer.
10. The manufacturing method as defined in claim 9, wherein the reflecting elements are provided on the first electrode layer by
applying a first mask layer (13) for masking regions (14) on the first electrode layer (3),
- applying a reflecting material, which is reflective to the light produced by the lighting apparatus, at least on un-masked regions (17) on the first electrode layer (3), removing the first mask layer.
11. The manufacturing method as defined in claim 10, wherein, before removing the first mask layer,
a second mask layer (18) is applied onto the reflecting material (16) in regions in which the reflecting material (16) is in contact with the first electrode layer (3), and parts of the reflecting material (16), which are not covered by the second mask layer (18), are removed.
12. The manufacturing method as defined in claim 10, wherein the first mask layer is applied by printing a first mask material.
13. The manufacturing method as defined in claim 8, wherein the reflecting elements are provided on the substrate and the first electrode layer is provided on the reflecting elements.
14. A manufacturing apparatus for manufacturing a lighting apparatus for producing light, the manufacturing apparatus comprising:
a substrate provision unit (301, 302, 303, 304, 305, 306) for providing a substrate (2) with a first electrode layer (3) and with non-transparent reflecting elements having reflecting surfaces enclosing an angle with the substrate being not 90 degrees,
a light emission layer application unit (308) for applying a light emission layer on the first electrode layer and on the reflecting material,
a second electrode layer application unit (309) for applying a second electrode layer on the light emission layer.
15. A manufacturing computer program for manufacturing a lighting apparatus for producing light, the manufacturing computer program comprising program code means for causing a manufacturing apparatus as defined in claim 14 to carry out the steps of the manufacturing method as defined in claim 8, when the manufacturing computer program is run on a computer controlling the manufacturing apparatus.
PCT/IB2012/056275 2011-11-11 2012-11-09 Lighting apparatus and manufacturing method for manufacturing the lighting apparatus WO2013068965A2 (en)

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