OLED device having curved viewing surface

• US 20060273304A1
• Filed: 06/07/2005
• Published: 12/07/2006
• Est. Priority Date: 06/07/2005
• 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 7,368,307 B2
• Time in Patent Office: Days
• US Class Current: 257/40
• CPC Class Codes: H10K 2102/311 Flexible OLED
• CPC Class Codes: H10K 50/80 Constructional details
• CPC Class Codes: H10K 50/841 Self-supporting sealing arrangements
• CPC Class Codes: H10K 50/8428 Vertical spacers, e.g. arranged between the sealing arrangement and the OLED
• CPC Class Codes: H10K 77/10 Substrates, e.g. flexible substrates
• CPC Class Codes: H10K 77/111 Flexible substrates
• CPC Class Codes: Y02E 10/549 Organic PV cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A method of manufacturing an OLED device with a curved light-emitting surface comprising: a) forming a flexible substrate and providing the flexible substrate in a flat configuration; b) forming one or more OLEDs having a first electrode, one or more layers of organic material, at least one of which is light emitting formed over the first electrode, and a second electrode formed over the one or more layers of organic material, on the substrate; c) forming a rigid, curved, encapsulating cover; d) conforming the flexible substrate, electrodes, and one or more layers of organic material to the rigid, curved, encapsulating cover; and e) sealing the conformed flexible substrate, electrodes, and one or more layers of organic material to the rigid, curved, encapsulating cover.

Claims

1. A method of manufacturing an OLED device with a curved light-emitting surface comprising:

a) forming a flexible substrate and providing the flexible substrate in a flat configuration;

b) forming one or more OLEDs having a first electrode, one or more layers of organic material, at least one of which is light emitting formed over the first electrode, and a second electrode formed over the one or more layers of organic material, on the substrate;

c) forming a rigid, curved, encapsulating cover;

d) conforming the flexible substrate, electrodes, and one or more layers of organic material to the rigid, curved, encapsulating cover; and

e) sealing the conformed flexible substrate, electrodes, and one or more layers of organic material to the rigid, curved, encapsulating cover.

2. The method of claim 1, wherein the rigid, curved encapsulating cover includes at least two opposing raised edges, and an outside edge of the flexible substrate is positioned adjacent to an inside surface of each raised edge.

3. The method of claim 2, wherein the rigid, curved encapsulating cover includes two pairs of opposing raised edges, and an outside edge of the flexible substrate is positioned adjacent to a corresponding surface of each raised edge.

4. The method of claim 2, wherein the rigid, curved encapsulating cover is sealed to the flexible substrate along the perimeter of a main surface of the flexible substrate and/or along the outside edge of the flexible substrate.

5. The method of claim 1, wherein the flexible substrate is conformed to the curved cover so that the OLEDs are on the concave side of the curved cover.

6. The method of claim 1, wherein the flexible substrate is conformed to the curved cover so that the OLEDs are on the convex side of the curved cover.

7. The method of claim 1, further including providing spacers located between the OLEDs and a main surface of the rigid, curved encapsulating cover to prevent the OLEDs from contacting the main surface of the encapsulating cover.

8. The method of claim 7, wherein the spacers comprise raised areas formed over the substrate which project above the OLEDs, or raised areas formed over the main surface of the encapsulating cover.

9. The method of claim 7, wherein the spacers are formed separately and located over the OLEDs.

10. The method of claim 7, further including the step of providing an adhesive on the spacers.

11. The method of claim 1, wherein the substrate is initially formed with a curved surface and subsequently compressed or tensioned to provide the flat configuration.

12. The method of claim 11, wherein the substrate is initially formed with a curved surface that conforms to the rigid, curved encapsulating cover.

13. The method of claim 1, wherein the substrate and/or cover comprises glass.

14. An OLED device with a curved light-emitting surface manufactured according to the method of claim 1.

15. The OLED device claimed in claim 14, wherein the OLED device is a panoramic display, a desktop display, a computer monitor, or an area illumination light source.

16. The OLED device claimed in claim 14, further comprising spacers located between the OLEDs and a main surface of the rigid, curved encapsulating cover preventing the OLEDs from contacting the main surface of the encapsulating cover.

17. The OLED device claimed in claim 14, further comprising a rigid, curved substrate affixed to the flexible substrate.

18. The OLED device of claim 14, wherein the rigid, curved encapsulating cover includes at least two opposing raised edges, and an outside edge of the flexible substrate is positioned adjacent to an inside surface of each raised edge.

19. The OLED device claimed in claim 18, wherein the two opposing raised edges comprise edge lips extending around the outside edges and over a peripheral portion of the side of the substrate opposite the OLEDs.

20. The OLED device claimed in claim 18, further comprising connecting wires connected to the electrodes and passing through an opening in at least one raised edge.