Barrier stack

[0002] The present invention relates generally to encapsulating or sealing of devices, such as organic light emitting diode (OLED) devices.

[0003] FIG. 1 shows an OLED device 100 which serve, for example, as a display in various types of consumer electronic products, including cellular phones, cellular smart phones, personal organizers, pagers, advertising panels, touch screen displays, teleconferencing and multimedia products, virtual reality products, and display kiosks.

[0004] The OLED device comprises a functional stack formed on a substrate 101. The functional stack comprises of one or more organic functional layers 110 between two conductive layers 105 and 115 which serve as electrodes (cathode and anode). The conductive layers are patterned as desired, for example, to form a pixelated, a segmented, or other types of devices. Charge carriers are injected through the cathodes and anodes via bond pads 150 for recombination in the functional layers. The recombination of the charge carriers causes the functional layer to emit visible radiation. The device is encapsulated with a cap 160. OLED devices require hermetic sealing since the active components, such as the cathode, are adversely impacted by moisture and oxygen.

[0005] Flexible OLED devices formed on polymeric substrates have been investigated. Due to low barrier performance of the polymeric material to moisture and oxygen, the substrate needs to be coated with a barrier. Typically the barrier comprises oxide or nitrides, such as aluminum oxide, silicon oxide, or silicon nitride. The barrier layer is formed on the polymeric substrate by physical vapor deposition (PVD) or chemical vapor deposition (CVD). When a barrier layer is deposited on a polymeric material, imperfections such as pinholes, cracks, and grain boundaries occur. Such imperfections adversely impact the barrier characteristics of the barrier layer. Multiple metal oxide layers have been proposed to improve barrier performance. However, the use of multiple metal oxide layers still has not satisfied the barrier performance necessary for OLED devices because pinholes or imperfections tend to propagate to the subsequent layers.

[0006] As evidenced from the foregoing discussion, it is desirable to provide improved barrier for OLED devices, particularly for flexible OLED devices.

[0007] The invention relates to a barrier stack for improved sealing of a device, such as an OLED device. The barrier stack comprises first and second base layers. The first base layer includes a flexible substrate having at least one of its surfaces coated with a barrier layer. The second base layer includes a flexible substrate having at least one of its surfaces coated with a barrier layer. The base layers are bonded together with a high barrier adhesive. In another embodiment, the barrier layer is coated with a liner layer to seal the micro and nano defects on the barrier layer to enhance the barrier property of the barrier stack. In yet another embodiment, a foil, such as aluminum or copper, is provided between the base layer.

[0008] FIG. 1 shows a conventional OLED device;

[0009] FIGS. 2-4 show barrier stacks in accordance with various embodiments of the invention;

[0010] FIG. 5 shows an OLED device in accordance with one embodiment of the invention; and

[0011] FIGS. 6-7 show an OLED device in accordance with another embodiment of the invention.

[0012] In accordance with the invention, an improved barrier stack is provided. The barrier stack serves to improve hermetic sealing of devices cost effectively. Additionally, the barrier stack can be used as a substrate on which active components of devices can be fabricated as well as a device package. Although the invention is described in the context of an OLED device, it is generally applicable for other types of devices, particularly those which require hermetic sealing to protect the components from the environment.

[0013] Referring to FIG. 2, a barrier stack 201 in accordance with one embodiment of the invention is shown. The barrier stack comprises a plurality of base layers 210 bonded together. As shown, the barrier stack includes first and second base layers. Barrier stacks with more than two base layers are also useful. In one embodiment, a base layer comprises a flexible support or substrate 215. The flexible substrate is formed from, for example, polymeric material such as polyester, polyethylene glycol terephthalate (PET), polypropylene, and polyamide such as nylon, PEN, PES, or PC. Other flexible materials can also be used to form the flexible substrate. Polymeric materials advantageously enable fabricating of devices using a roll-to-roll process.

[0014] At least one major surface of the support layer is coated with a barrier layer 217 for inhibiting the passage of moisture or oxygen therethrough. Preferably, the flexible substrate is coated on both major surfaces with a barrier layer. Providing a combination of support layers where some are coated on one major surface and other coated on both surfaces is also useful. Typically, the barrier layer comprises a metal oxide such as, for example, aluminum oxide or silicon oxide. Other materials such as nitrides can also be used to form the barrier layer. Various conventional techniques can be used to form the barrier layer on the plastic support layer. Such techniques include, for example, sputtering, electron beam evaporation, plasma evaporation or chemical vapor evaporation or plasma polymerization.

[0015] The flexible substrate and barrier layers are formed from, for example, transparent materials. The use of transparent materials allows the OLED device to be viewed through the barrier stack. Non-transparent materials can also be used to from the barrier stack, particularly for applications which do not require transparency.

[0016] If the barrier stack serves as the substrate or support on which OLED devices are fabricated, a conductive layer 250 is deposited on its upper surface. For example, the conductive layer is deposited on the barrier layer. The conductive layer serves as an electrode of the OLED device. In one embodiment, the conductive layer comprises a transparent conductive layer formed from indium tin oxide (ITO). Other types of conductive materials, such as indium zinc oxide (IZO) or zinc oxide (ZO), are also useful to form the conductive layer. Various conventional techniques including sputtering, PVD or CVD vacuum processes can be used to form the conductive layer. The conductive layer can be patterned as desired to form, for example, the anode or anodes of the OLED device.

[0017] In an alternative embodiment, as shown in FIG. 3, a liner 340 can be deposited on the barrier layer to provide a lined barrier layer. The liner layer provides surface smoothness as well as sealing micro and nano defects in the barrier layer. In one embodiment, the liner layer comprises an organic material such as acrylic. Epoxy-based (e.g., heat or UV cured epoxy-based hard coat), silicone-based, or parylene types of materials are also useful to serve as the liner layer. The organic material can be deposited on the barrier layer using various conventional techniques such as CVD, vacuum evaporation, spin coating or lamination. Additional barrier layers with a liner layer between two barrier layers can also be provided. However, it is not necessary that the final layer of the stack is a liner layer.

[0018] In one embodiment, the base layers are bonded together with an adhesive 230. The adhesive can comprises a high barrier adhesive such as UV or heat cured laminating epoxy. Other types of high barrier adhesives are also useful. The adhesive seals imperfections in the barrier layers, thus improving the barrier performance of the barrier layers. Tests have shown that the barrier layer performance can be enhanced by 10 to 100 folds as compared to base layers which are not bonded with an adhesive. The base layers can be bonded using conventional lamination techniques such as UV or heat curing adhesive bonding.

[0019] The base layers can be bonded together in any configuration. For example, the base layers can all be coated on both major surfaces with the barrier layer, on just one major surface, or a combination of one and both major surfaces. Preferably, the base layers are bonded such that at least a barrier layer of one of the two adjacent base layers is in contact with the adhesive. For example, if only one major surface of the base layers is coated, the barrier layer (or liner layer if barrier layer is coated) of one of the base layer is bonded to the flexible substrate of the other base layer. Bonding barrier layer of one base layer to the barrier layer of the other base layer is also useful. If the barrier stack is used as the substrate for forming OLEDs, the base layers are bonded to provide the conductive layer on the upper surface of the barrier stack. Alternatively, the conductive oxide layer (e.g., ITO) can be formed on the upper surface of the barrier stack after the base layers are bonded together.

[0020] Optionally, a foil 450 can be provided between two base layers, as shown in FIG. 4. The foil, in one embodiment, comprises aluminum. Other types of foils, such as copper, are also useful. The foil further improves the barrier properties of the barrier stack since it generally does not have any defects such as pinholes or pores. Furthermore, the foil has high flexibility after lamination. The thickness of the foil, for example, is less than 200 um.

[0021] FIG. 5 shows an OLED device in accordance with one embodiment of the invention. A barrier stack 201aserves as the substrate on which OLED active components 560 are formed using conventional techniques. Such techniques are described in, for example, U.S. Pat. No. 4,720,432 and Burroughes et. al, Nature 347 (1990) 539, which are herein incorporated by reference for all purposes. The OLED active components include, for example, OLED pixels or segments. A protective organic and barrier layers 565 and 567 can be provided over the OLED active components. In one embodiment, the protective organic layer comprises an acrylic-based hard coat while the barrier layer comprises a metal oxide. Other types of organic protective and barrier layers can also be used.

[0022] A second barrier stack 201bis bonded to the barrier stack 201awith an adhesive 580, encapsulating the OLED components. Various types of adhesives, such as UV cured epoxy, heat cured epoxy, UV and heat cured epoxy, or any other acrylic based high barrier adhesives, can be used.

[0023] FIGS. 6-7 show a secondary encapsulation for the OLED device 501 in accordance with one embodiment of the invention. Referring to FIG. 6, first and second barrier stacks 601a-b, which are larger than the OLED device, are provided. The barrier stacks are laminated together, as shown in FIG. 7, using conventional lamination techniques. Preferably, the barrier stacks are laminated with a high barrier adhesive. The secondary encapsulation surrounds the sides of the OLED device, thus preventing permeation of moisture or oxygen therethrough.

[0024] While the invention has been particularly shown and described with reference to various embodiments, it will be recognized by those skilled in the art that modifications and changes may be made to the present invention without departing from the spirit and scope thereof. The scope of the invention should therefore be determined not with reference to the above description but with reference to the appended claims along with their full scope of equivalents.