Diffusion barrier coatings having graded compositions and devices incorporating the same

• US 7,486,020 B2
• Filed: 12/02/2005
• Issued: 02/03/2009
• Est. Priority Date: 09/11/2002
• Status: Expired due to Term

• Current Assignee: BOE Technology Group Co., Ltd.
• Original Assignee: General Electric Company
• Inventors: Schaepkens, Marc, Flanagan, Kevin Warner
• Primary Examiner(s): MACCHIAROLO, PETER J
• Application Number:
  US11/292,281
• Publication Number:
  US 20060132032A1
• Time in Patent Office: 1,159 Days
• Field of Search: 313/512, 427/256, 428/626, 428/547, 428/610
• US Class Current: 313/512
• CPC Class Codes: B82Y 20/00 Nanooptics, e.g. quantum optics or photonic crystals
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C23C 16/30 Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
• CPC Class Codes: G02F 1/133305 Flexible substrates, e.g. plastics, organic film
• CPC Class Codes: G02F 2201/50 Protective arrangements
• CPC Class Codes: H10K 2101/80 Composition varying spatially, e.g. having a spatial gradient
• CPC Class Codes: H10K 2102/311 Flexible OLED
• CPC Class Codes: H10K 2102/331 Nanoparticles used in non-emissive layers, e.g. in packaging layer
• CPC Class Codes: H10K 50/125 specially adapted for multicolour light emission, e.g. for emitting white light
• CPC Class Codes: H10K 50/844 Encapsulations
• CPC Class Codes: H10K 50/854 comprising scattering means
• CPC Class Codes: H10K 59/877 comprising scattering means
• CPC Class Codes: Y10T 428/12021 having composition or density gradient or differential porosity
• CPC Class Codes: Y10T 428/1321 Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1352 Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/31667 Next to addition polymer from unsaturated monomers, or aldehyde or ketone condensation product

Abstract

A composite article comprises a substrate having at least a substrate surface and a graded-composition coating disposed on a substrate surface. The composition of the coating material varies substantially continuously across its thickness. The coating reduces the transmission rates of oxygen, water vapor, and other chemical species through the substrate such that the composite article can be used effectively as a diffusion barrier to protect chemically sensitive devices or materials. An organic light-emitting device incorporates such a composite article to provide an extended life thereto.

Claims

1. An article comprising:

a member having a surface;

an organic light emitting diode (OLED) disposed on said surface; and

a coating comprising a coating material a composition of which varies substantially continuously across a thickness of said coating, said coating disposed on said OLED and contacting said surface so as to encapsulate said OLED within said coating and said surface,

wherein said coating material comprises an inorganic and an organic material.

2. The article of claim 1 wherein said member has a reflective surface.

3. The article of claim 1 wherein said member comprises a metal.

4. The article of claim 3 including an insulating layer.

5. The article of claim 1 wherein said member comprises glass.

6. The article of claim 1 wherein the composition of said coating material varies across a thickness of said coating such that a graph of the percent composition of one of the components of the coating material versus the depth of the coating has plural peaks.

7. The article of claim 6 wherein said plural peaks are substantially the same height.

8. The article of claim 6 wherein the plurality of peaks is at least three.

9. The article of claim 8 wherein the height of the peaks changes as a function of depth.

10. An article comprising:

a layer having a surface;

an organic light emitting diode (OLED) disposed on said surface; and

a coating comprising a coating material a composition of which varies substantially continuously across a thickness of said coating, said coating disposed on said OLED and contacting said surface so as to encapsulate said OLED within said coating and said surface,

wherein said coating material comprises an inorganic and an organic material.

11. The article of claim 10 wherein said layer has a reflective surface.

12. The article of claim 10 wherein said layer comprises a metal.

13. The article of claim 12 including an insulating layer.

14. The article of claim 10 wherein said layer comprises glass.

15. The article of claim 10 wherein the composition of said coating material varies across a thickness of said coating such that a graph of the percent composition of one of the components of the coating material versus the depth of the coating has plural peaks.

16. The article of claim 15 wherein said plural peaks are substantially the same height.

17. The article of claim 15 wherein the plurality of peaks is at least three.

18. The article of claim 17 wherein the height of the peaks changes as a function of depth.

19. An article comprising:

a coating comprising a coating material a composition of which varies substantially continuously across a thickness of said coating; and

an organic light emitting diode (OLED) having a first surface in contact with a member and a second surface in contact with said coating,

wherein said coating material comprises an inorganic and an organic material.

20. The article of claim 19 wherein said coating and said member encapsulate said OLED.

21. The article of claim 19 wherein said coating encapsulates said member and said OLED.

22. The article of claim 19 wherein said member has a reflective surface.

23. The article of claim 19 wherein said member comprises a metal.

24. The article of claim 23 including an insulating layer.

25. The article of claim 19 wherein said member comprises glass.

26. The article of claim 19 wherein the composition of said coating material varies across a thickness of said coating such that a graph of the percent composition of one of the components of the coating material versus the depth of the coating has plural peaks.

27. The article of claim 26 wherein said plural peaks are substantially the same height.

28. The article of claim 26 wherein the plurality of peaks is at least three.

29. The article of claim 28 wherein the height of the peaks changes as a function of depth.