Flexible high-temperature ultrabarrier

• US 7,018,713 B2
• Filed: 04/02/2003
• Issued: 03/28/2006
• Est. Priority Date: 04/02/2003
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Padiyath, Raghunath, Roehrig, Mark A.
• Primary Examiner(s): Williams, Joseph
• Assistant Examiner(s): QUARTERMAN, KEVIN J
• Application Number:
  US10/405,284
• Publication Number:
  US 20040195967A1
• Time in Patent Office: 1,091 Days
• Field of Search: 313/498, 313/503, 313/506, 313/512, 313/609, 428/411.1, 428/412, 428/421, 428/422, 428/422.8, 428/451, 428/473.5, 428/520
• US Class Current: 428/411.1
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: C09K 2323/00 Functional layers of liquid crystal optical display excluding electroactive liquid crystal layer characterised by chemical composition
• CPC Class Codes: C09K 2323/03 Viewing layer characterised by chemical composition
• CPC Class Codes: C09K 2323/035 Ester polymer, e.g. polycarbonate, polyacrylate or polyester
• CPC Class Codes: G02F 1/1333 Constructional arrangements; Manufacturing methodsG02F1/135, G02F1/136 take precedence
• CPC Class Codes: H10K 2102/311 Flexible OLED
• CPC Class Codes: H10K 50/80 Constructional details
• 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 428/264 Up to 3 mils
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/3154 Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31544 Addition polymer is perhalogenated
• CPC Class Codes: Y10T 428/31786 Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31928 Ester, halide or nitrile of addition polymer

Abstract

A flexible barrier assembly having a flexible visible light-transmissive substrate having a Tg greater than or equal to that of heat-stabilized polyethylene terephthalate (“HSPET”) overcoated with a first polymer layer having a Tg greater than or equal to that of HSPET and further overcoated with at least two visible light-transmissive inorganic barrier layers separated by at least one second polymer layer having a Tg greater than or equal to that of HSPET can be used to mount, cover, encapsulate or form moisture- and oxygen-sensitive articles such as organic light emitting devices and light valves.

Claims

1. A barrier assembly comprising a flexible visible light-transmissive substrate having a Tg greater than or equal to that of HSPET overcoated with a first polymer layer having a Tg greater than or equal to that of HSPET and further overcoated with at least two visible light-transmissive inorganic barrier layers separated by at least one second polymer layer having a Tg greater than or equal to that of HSPET, the barrier assembly having an oxygen transmission rate less than 0.005 cc/m²/day at 23°

C. and 90% RH.

2. A barrier assembly according to claim 1 wherein the substrate has a Tg greater than that of PMMA.

3. A barrier assembly according to claim 1 wherein the substrate has a Tg of at least about 120°

C.

4. A barrier assembly according to claim 1 wherein the substrate comprises heat-stabilized PET or polyethylene naphthalate.

5. A barrier assembly according to claim 1 wherein the substrate comprises polyoxymethylene, polyvinylnaphthalene, polyetheretherketone, fluoropolymer, polycarbonate, poly α

-methyl styrene, polysulfone, polyphenylene oxide, polyetherimide, poly ether sulfone, polyamideimide, polyimide or polyphthalamide.

6. A barrier assembly according to claim 1 wherein the first or second polymer layer has a Tg greater than that of PMMA.

7. A barrier assembly according to claim 1 wherein the first and second polymer layers have a Tg of at least about 150°

C.

8. A barrier assembly according to claim 1 wherein the first or second polymer layer comprises a polymer of cyclohexane dimethanol diacrylate ester, isobomyl methacrylate, cyclic diacrylate or tris (2-hydroxy ethyl) isocyanurate triacrylate.

9. A barrier assembly according to claim 1 wherein the first, second, and any further polymer layers in the barrier assembly have a Tg greater than or equal to that of PMMA.

10. A barrier assembly according to claim 1 wherein at least one inorganic barrier layer comprises a metal oxide.

11. A barrier assembly according to claim 1 wherein at least one inorganic barrier layer comprises indium tin oxide.

12. A barrier assembly according to claim 1 wherein at least one inorganic barrier layer comprises silicon oxide or aluminum oxide.

13. A barrier assembly according to claim 1 wherein at least one inorganic barrier layer comprises a mixed oxide of aluminum and silicon.

14. A barrier assembly according to claim 1 having a water vapor transmission rate less than 0.005 g/m²/day at 50°

C. and 100% relative humidity.

15. A barrier assembly according to claim 1 having a water vapor transmission rate less than 0.005 g/m²/day at 85°

C. and 100% relative humidity.

16. A barrier assembly according to claim 1 having a Tvis of at least about 60%.

17. A barrier assembly according to claim 1 wherein at least part of the assembly is overcoated with a conductive layer or electrode.

18. A barrier assembly according to claim 17 wherein the conductive layer or electrode is visible light-transmissive.

19. A barrier assembly according to claim 1 wherein all of the polymer layers in the barrier assembly are crosslinked.

20. A barrier assembly according to claim 1 having at least three visible light-transmissive inorganic barrier layers separated by second polymer layers having a Tg of at least about 150°

.