TRANSPARENT CONDUCTIVE ARTICLES AND METHODS OF MAKING SAME

• US 20110074282A1
• Filed: 12/10/2010
• Published: 03/31/2011
• Est. Priority Date: 11/02/1998
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Bright, Clark I.
• Granted Patent: US 8,241,752 B2
• Time in Patent Office: Days
• US Class Current: 313/504
• CPC Class Codes: C23C 16/0272 Deposition of sub-layers, e.g. to promote the adhesion of the main coating
• CPC Class Codes: C23C 16/545 for coating elongated substrates
• CPC Class Codes: G02F 1/133305 Flexible substrates, e.g. plastics, organic film
• CPC Class Codes: G02F 1/133345 Insulating layers G02F1/1335, G02F1/1337, G02F1/135, G02F1/136 take precedence
• CPC Class Codes: H10K 2102/311 Flexible OLED
• CPC Class Codes: H10K 50/81 Anodes
• CPC Class Codes: H10K 50/816 Multilayers, e.g. transparent multilayers
• CPC Class Codes: H10K 50/8445 multilayered coatings having a repetitive structure, e.g. having multiple organic-inorganic bilayers
• 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
• CPC Class Codes: Y10T 428/12576 Boride, carbide or nitride component
• CPC Class Codes: Y10T 428/31667 Next to addition polymer from unsaturated monomers, or aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31678 Of metal
• CPC Class Codes: Y10T 428/31681 Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
• CPC Class Codes: Y10T 428/31692 Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31794 Of cross-linked polyester
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer

Abstract

A lightweight, flexible, plastic substrate is coated with at least one layer, such that the substrate has desired barrier and electrode characteristics useful in constructing OLED displays. The layer has both a low enough resistance to function as an electrode for the display, and low oxygen and moisture permeability. The display is thereby protected from oxygen and moisture degradation. For lower permeability and/or higher conductivity, multiple alternating layers of barrier materials and conductive materials may be applied. The barrier material includes at least one of a thin metallic film, an organic polymer, a thin transparent dielectric, a thin transparent metal nitride, and a thin transparent conductive oxide. The conductive material includes at least one of a thin transparent conductive oxide, a thin transparent metallic film, and a thin transparent metal nitride. Preferably, a multilayer polymer base coat is deposited over the substrate to exclude moisture and atmospheric gases.

Claims

1. An OLED comprising a flexible plastic substrate coated with multiple layers of transparent electrically conductive metal nitride separated by one or more layers of polymer, the OLED being sufficiently flexible to be processable in a web coater, wherein the OLED has a visible light transmittance of about 80-85%.

2. The OLED of claim 1, wherein the transparent electrically conductive metal nitride is selected from the group consisting of silicon nitride, aluminum nitride, and nitrides of Group IIIA and IVA elements of the Periodic Table.

3. An OLED comprising a flexible plastic substrate coated with multiple layers of transparent electrically conductive metal separated by one or more vacuum-deposited in-situ polymerized layers of polymer, wherein the OLED has a visible light transmittance of about 80-85%.

4. The OLED according to claim 3, wherein the multiple layers of transparent electrically conductive metal are in three layer configurations comprising a transparent electrically conductive oxide layer, the transparent electrically conductive metal layer, and another transparent electrically conductive oxide layer.

5. The OLED according to claim 3, wherein, the OLED does not comprise a reflective metal layer.

6. An OLED comprising a flexible substrate, at least one layer of polymer and an optically enhanced transparent conductive three layer configuration comprising adjacent layers of:

(a) electrically conductive oxide, metal, and conductive oxide;

(b) electrically conductive oxide, metal nitride, and conductive oxide;

(c) metal nitride, metal, and metal nitride;

or

(d) electrically conductive oxide, metal, and metal oxide,

wherein the OLED has a visible light transmittance of about 80-85%.

7. The OLED according to claim 6, wherein the transparent electrically conductive three layer configuration comprises adjacent layers of electrically conductive oxide, electrically conductive metal nitride, and electrically conductive oxide.

8. The OLED according to claim 6, wherein the transparent electrically conductive three layer configuration comprises adjacent layers of silicon nitride, metal, and another metal nitride.

9. The OLED according to claim 6, comprising:

(a) a first transparent electrically conductive three layer configuration, and

(b) a layer of transparent electrically conductive oxide or a second transparent electrically conductive three layer configuration,

wherein (a) and (b) are separated by one or more layers of polymer.

10. The OLED according to claim 6, wherein all electrically conductive layers are electrically connected in parallel.

11. The OLED according to claim 6, further comprising an electrically conductive oxide layer of one or more of cadmium oxide, tin oxide, indium oxide, zinc oxide, gallium-containing oxide, and magnesium oxide, which oxides may be doped or undoped.

12. The OLED according to claim 6, further comprising a metal nitride layer of one or more nitride of a Group III or IV element of the Periodic Table.

13. A method for modifying a light emitting surface of an OLED, the process comprising the steps of:

(a) providing a flexible plastic substrate which optionally has a hard coat;

(b) depositing over the substrate multiple layers of transparent electrically conductive oxide that are separated by one or more layers of in-situ polymerized organic monomer; and

(c) applying the flexible plastic substrate to a light emitting surface of an OLED,

wherein the OLED has a visible light transmittance of about 80-85% after steps (a)-(c).

14. The method according to claim 13, further comprising applying a polymeric base coat to smooth the substrate prior to deposition of the transparent electrically conductive oxide.

15. The method according to claim 13, further comprising heating the substrate during or after deposition of the transparent electrically conductive oxide.

16. The method according to claim 13, further comprising depositing the transparent electrically conductive oxide in a hydrogen-containing plasma.

17. The method according to claim 13, wherein the multiple layers are deposited in a single vacuum chamber.

18. The method according to claim 13, further comprising electrically connecting all transparent electrically conductive oxide layers in parallel.

19. The method according to claim 13, further comprising contacting the transparent conductive oxide layers with a roller without causing cracking or crazing of the electrically conductive oxide layers sufficient to reduce electrical conductivity.

20. A process for fabricating an OLED, the process comprising the steps of:

(a) providing a flexible plastic substrate;

(b) depositing over the substrate a layer of in-situ polymerized organic monomer and an optically enhanced transparent electrically conductive three layer configuration comprising layers of electrically conductive oxide, metal nitride or dielectric;

metal or metal nitride; and

electrically conductive oxide, metal nitride or dielectric;

(c) applying the flexible plastic substrate to an OLED to obtain a visible light transmittance of about 80-85%; and

optionally

(d) electrically connecting all electrically conductive layers in parallel.