Dynamic OLED lighting

• US 8,907,560 B2
• Filed: 05/12/2011
• Issued: 12/09/2014
• Est. Priority Date: 05/12/2011
• Status: Active Grant

• Current Assignee: Universal Display Corporation
• Original Assignee: Universal Display Corporation
• Inventors: Levermore, Peter, Rajan, Kamala, Mandlik, Prashant, Krall, Emory, Pang, Huiqing, Ma, Ruiqing
• Primary Examiner(s): Jung, Michael
• Assistant Examiner(s): Dulka, John P
• Application Number:
  US13/106,660
• Publication Number:
  US 20120286245A1
• Time in Patent Office: 1,307 Days
• Field of Search: 313/511, 257/40, 257/99, 257/100, 257/E21.018
• US Class Current: 313/511
• CPC Class Codes: H10K 2102/311 Flexible OLED
• CPC Class Codes: H10K 77/111 Flexible substrates
• CPC Class Codes: Y02E 10/549 Organic PV cells

Abstract

A flexible OLED is provided on a flexible substrate. The flexible substrate has at least cut region. The substrate is expandable due to the separation of the flexible substrate at the cut region that is accommodated by bending of the flexible substrate. The substrate on which the flexible OLED is deposited on may be expanded without plastic deformation.

Claims

1. A first device comprising:

a flexible substrate having a length in a given direction and an outer perimeter;

at least one flexible OLED device deposited on the flexible substrate;

wherein the flexible substrate has at least one cut region;

wherein the at least one cut region does not bisect the outer perimeter and is not connected to the outer perimeter through another cut region;

wherein the flexible substrate is expandable due to separation of the flexible substrate at the at least one cut region that is accommodated by bending of the flexible substrate;

wherein at least one portion of the flexible substrate deforms out of plane due to the at least one cut region when a stretching force is applied to opposite ends of the first device in the given direction; and

wherein the length of the flexible substrate in the given direction increases.

2. The first device of claim 1, wherein the flexible substrate is expandable with minimal local strain in the plane of the first device within the active area of the OLED device.

3. The first device of claim 1, wherein the flexible substrate is expandable with minimal plastic deformation within the active area of the OLED device.

4. The first device of claim 1, wherein the first device has a first configuration that is planar, and a second configuration that is non-planar, wherein at least one pair of points on the first device have greater separation in the non-planar configuration than in the planar configuration.

5. The first device of claim 1, wherein:

the first device has a first configuration that is a developable surface;

wherein the first device has a second configuration that is expanded relative to the first configuration along a line that lies in the developable surface;

wherein the second configuration has a non-planar three dimensional geometry;

wherein the first device may reversibly adopt the first and second configurations with minimal plastic deformation within the active area of the OLED device.

6. The first device of claim 5, wherein the developable surface is a flat plane and the line is a straight line.

7. The first device of claim 1, wherein the first device further comprises at least one structurally weakened region that includes at least one of a scored region, perforated region, or folded region.

8. The first device of claim 7, wherein:

the OLED device is covered with a thin film encapsulation layer; and

the at least one structurally weakened region is substantially free of the thin film encapsulation layer.

9. The first device of claim 1, wherein the flexible substrate comprises metal foil, plastic, fabric, paper or combinations thereof

10. The first device of claim 9, wherein the metal foil comprises stainless steel foil, aluminum foil, copper foil or combinations thereof

11. The first device of claim 10, wherein the metal foil has a thickness of about 5 microns to about 300 microns.

12. The first device of claim 9, wherein the plastic comprises polyethylene terephthalate, polyethylene naphthalate, or combinations thereof.

13. The first device of claim 9, wherein the plastic has a thickness of about 5 microns to about 5000 microns.

14. The first device of claim 9, wherein the flexible substrate has a flexural rigidity from about 10^-6 Nm to about 1.0 Nm.

15. The first device of claim 9, wherein the flexible substrate has a flexural rigidity from about 10^-5 Nm to about 0.1 Nm.

16. The first device of claim 1, wherein the first device is a lamp.

17. The first device of claim 1, wherein the OLED conforms to the shape of the first device.

18. The first device of claim 1, wherein the OLED is in direct contact with the surface of the flexible substrate.

19. The first device of claim 1, wherein at least one layer is present between the OLED and the surface of the flexible substrate.

20. The first device of claim 1, wherein the flexible substrate further comprises a layer of insulating material deposited between the surface of the flexible substrate and the OLED.

21. The first device of claim 20, wherein the insulating material comprises a polyimide layer.

22. The first device of claim 20, wherein the insulating material comprises an inorganic dielectric layer.

23. The first device of claim 20, wherein the insulating material has a thickness of about 2 microns to about 20 microns.

24. The first device of claim 1, wherein the OLED device comprises a single pixel.

25. The first device of claim 1, wherein the OLED device comprises a plurality of pixels.

26. The first device of claim 25, wherein the plurality of pixels are connected in series.

27. The first device of claim 25, wherein the plurality of pixels are connected in parallel.

28. The first device of claim 1, wherein at least one portion of the surface of the flexible substrate can deform out of plane due to the at least one cut region.

29. The first device of claim 1, wherein at least one portion of the surface of the flexible substrate can deform out of plane due to at least one structurally weakened region.

30. The first device of claim 1, wherein the OLED device is covered with a thin film encapsulation layer.

31. The first device of claim 30, wherein the thin film encapsulation layer has a thickness of less than 10 microns.

32. The first device of claim 30, wherein a hard coat layer is present on top of the thin film encapsulation layer.

33. The first device of claim 1, Wherein the at least one cut region is formed prior to OLED deposition.

34. The first device of claim 1, wherein the OLED device has an active area and the active area comprises at least 30% of the surface area of the flexible substrate.

35. The first device of claim 1, wherein no complete OLED is deposited on a structurally weakened region.

36. The first device of claim 1, wherein at least one structurally weakened region is formed prior to OLED deposition.

37. The first device of claim 1, wherein the flexible substrate is reversibly expandable in the given direction such that the length of the flexible substrate in the given direction increases by at least 10%.

38. The first device of claim 1, wherein the flexible substrate is reversibly expandable in the given direction such that the length of the flexible substrate in the given direction increases by at least 20%.

39. The first device of claim 1, wherein the flexible substrate is-reversibly expandable in the given direction such that the length of the flexible substrate in the given direction increases by at least 50%.

40. The first device of claim 1, wherein the first device is attached to at least one contact region.

41. The first device of claim 1, wherein the first device is expandable by a mechanical means.

42. The first device of claim 41, wherein the mechanical means comprises a motor operably attached to a proximity sensor.

43. The first device of claim 1, wherein the first device is reversibly expandable.

44. The first device of claim 1, wherein one or more of the edges of the first device comprise a protective coating.

45. The first device of claim 1, wherein the first device contains no transistors.