Flexible substrate for OLED device

• US 8,981,363 B1
• Filed: 09/03/2013
• Issued: 03/17/2015
• Est. Priority Date: 09/03/2013
• Status: Active Grant

• Current Assignee: Universal Display Corporation
• Original Assignee: Universal Display Corporation
• Inventors: Premutico, Mauro, Ma, Ruiqing, Lin, Chun, Hack, Michael
• Primary Examiner(s): HO, TU TU V
• Application Number:
  US14/016,478
• Publication Number:
  US 20150060777A1
• Time in Patent Office: 560 Days
• Field of Search: 257/40, 257/59, 257/72, 438/99
• US Class Current: 257/40
• CPC Class Codes: G09F 9/301 flexible foldable or roll-able electronic displays, e.g. thin LCD, OLED
• CPC Class Codes: G09F 9/33 being semiconductor devices, e.g. diodes
• CPC Class Codes: H10K 2101/00 Properties of the organic materials covered by group H10K85/00
• CPC Class Codes: H10K 2102/311 Flexible OLED
• CPC Class Codes: H10K 2102/321 Inverted OLED, i.e. having cathode between substrate and anode
• CPC Class Codes: H10K 59/12 Active-matrix OLED [AMOLED] displays
• CPC Class Codes: H10K 59/32 Stacked devices having two or more layers, each emitting at different wavelengths
• CPC Class Codes: H10K 59/40 OLEDs integrated with touch screens
• 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

Flexible substrates and devices including flexible substrates are provided. In an embodiment, a flexible substrate includes a first glass substrate material and a first organic light emitting device, disposed over the first flexible substrate, which includes a first emissive layer The first flexible substrate may have a thickness of not more than 300 μm, a flexural rigidity of 10⁻¹ Nm to 10⁻⁶ Nm, a water vapor transmission rate of not more than 10⁻⁶ g per square meter per day, a refractive index of not more than 1.6, a glass transition temperature of at least 300 C, a Young'"'"'s modulus of 60 to 90 GPa, and/or an optical transmission of at least 85% for light in the range of 400 to 800 nm.

Claims

1. A first device comprising:

a first flexible substrate comprising a first glass substrate material; and

a first organic light emitting device, disposed over the first flexible substrate, comprising a first emissive layer having a first phosphorescent emissive material;

wherein the first flexible substrate has a thickness of not more than 300 μ

m; and

wherein the first glass substrate material has a flexural rigidity of 10<sup>−

1</sup> Nm to 10<sup>−

6</sup> Nm and a water vapor transmission rate of not more than 10<sup>−

6</sup> g per square meter per day.

2. The first device of claim 1, further comprising a communication device configured to receive consumer information.

3. The first device of claim 1, further comprising a mechanical mount suitable for attaching the device to a curved support surface.

4. The first device of claim 1, wherein the first glass substrate material has a refractive index of not more than 1.6.

5. The first device of claim 4, wherein the first glass substrate material has a refractive index of not more than 1.5.

6. The first device of claim 1, wherein the first glass substrate material has an optical transmission of at least 85% for light in the range of 400 to 800 nm.

7. The first device of claim 1, wherein the first glass substrate material has a glass transition temperature of at least 300°

C.

8. The first device of claim 1, wherein the first glass substrate material comprises a borosilicate glass.

9. The first device of claim 1, wherein the first glass substrate material has a thickness of not more than 200 μ

m.

10. The first device of claim 1, wherein the first flexible substrate has a thickness of not more than 100 μ

m.

11. The first device of claim 10, wherein the first flexible substrate has a thickness of not more than 50 μ

m.

12. The first device of claim 11, wherein the first flexible substrate has a thickness of not more than 30 μ

m.

13. The first device of claim 1, wherein the first flexible substrate has a thickness of at least 6 μ

m.

14. The first device of claim 1, wherein the first glass substrate material has a refractive index of at least 1.3.

15. The first device of claim 1, wherein the first glass substrate material has a glass transition temperature of at least 400°

C.

16. The first device of claim 1, wherein the first glass substrate material has a glass transition temperature of at least 500°

C.

17. The first device of claim 1, wherein the first glass substrate material has a flexural rigidity of not more than about 10⁻

1 Nm to 10<sup>−

4</sup> Nm.

18. The first device of claim 1, wherein the first glass substrate material has a Young'"'"'s modulus of 60 to 90 GPa.

19. The first device of claim 1, wherein the first organic light emitting device emits white light, and wherein the first emissive material emits light having a peak wavelength in the visible spectrum of 530 nm to 580 nm.

20. The first device of claim 1, further comprising a second organic light emitting device disposed over the first flexible substrate, which emits light having a peak wavelength in the visible spectrum of 500-600 nm;

wherein the second organic light emitting device comprises a second emissive layer having a phosphorescent second emissive material.

21. The first device of claim 20, wherein the first organic light emitting device emits light having a peak wavelength in the visible spectrum of 600-700 nm.

22. The first device of claim 21, wherein the second emissive layer further comprises a first host material and a second host material.

23. The first device of claim 21, further comprising a third organic light emitting device disposed over the first flexible substrate, which emits light having a peak wavelength in the visible spectrum of 400-500 nm;

wherein the third organic light emitting device comprises a third emissive layer having a third emitting material.

24. The first device of claim 23, wherein the third emitting material is fluorescent.

25. The first device of claim 23, wherein the third emitting material is phosphorescent.

26. The first device of claim 25, further comprises a fourth organic light emitting device disposed over the first flexible substrate, which emits light having a peak wavelength in the visible spectrum of 400-500 nm;

wherein the fourth organic light emitting device comprises a fourth emissive layer having a fourth emissive material; and

wherein the peak wavelength in the visible spectrum of light emitted by the fourth organic light emitting device is at least 4 nm less than the peak wavelength in the visible spectrum of light emitted by the third organic light emitting device.

27. The first device of claim 1, wherein the first device further comprises a barrier layer disposed over the first organic light emitting device.

28. The first device of claim 27, wherein the barrier layer comprises a mixture of a polymeric material and a non-polymeric material.

29. The first device of claim 27, wherein the first flexible substrate has a first surface, a first side, and a first edge where the first surface meets the first side;

wherein the first organic light emitting device has a second side;

wherein at least a portion of the second side is disposed within approximately 3 mm from the first edge; and

wherein the barrier layer covers at least a portion of the first edge, at least a portion of the first side, and at least the a portion of the second side.

30. The first device of claim 1, wherein the first device further comprises a second flexible substrate disposed over the first organic light emitting device.

31. The first device of claim 1, further comprising a flexible layer that is touch sensitive and can produce an electrical signal in response to a touch action received by the flexible layer.

32. The first device of claim 30, wherein the second flexible substrate has a thickness of not more than 300 μ

m.

33. The first device of claim 30, wherein the second flexible substrate comprises a second glass substrate material having a flexural rigidity of 10⁻

1 Nm to 10<sup>−

6</sup> Nm and a water vapor transmission rate of not more than 10<sup>−

6</sup> g per square meter per day.

34. The first device of claim 33, wherein the second glass substrate material comprises a borosilicate glass.

35. The first device of claim 30, wherein the second glass substrate material is the same material as the first substrate glass material.

36. The first device of claim 1, wherein the first device further comprises a second organic light emitting device disposed in a stack over the first organic light emitting device.

37. The first device of claim 1, wherein the first device is a consumer product.

38. The first device of claim 1, wherein the first device comprises a lighting panel.

39. The first device of claim 1, wherein the first device is a rollable display or a rollable lighting device.

40. The first device of claim 1, further comprising a color filter in optical communication with the first organic light emitting device.

41. The first device of claim 1, further comprising a touch sensitive surface.

42. The first device of claim 1, further comprising an outcoupling component in optical communication with the first organic light emitting device.

43. The first device of claim 1, wherein the first device is a display.

44. The first device of claim 1, further comprising at least one thin film transistor (TFT) electrically connected to the first organic light emitting device, and configured to be flexible with the substrate.

45. The first device of claim 1, wherein the first device is transparent.

46. The first device of claim 1, wherein the first organic light emitting device is a top-emitting device.

47. The first device of claim 1, wherein the first organic light emitting device is a bottom-emitting device.

48. The first device of claim 1, wherein all external electrical connections for the first device are disposed on one edge of the device.

49. The first device of claim 1, wherein the first device has a total thickness of not more than 500 μ

m.

50. The first device of claim 1, wherein the first device has a total thickness of not more than 1,000 μ

m.

51. The first device of claim 1, further comprising at least one electrical component selected from the group consisting of a timing component, a power source, a controller, a computer-readable memory element, and logic circuitry.

52. The first device of claim 1, wherein the first device has a bending length of about 1.0 cm to about 30.0 cm.

53. The first device of claim 52, wherein the first device has a bending length of about 3.0 cm to about 15.0 cm.

54. A consumer information display panel, comprising:

the first device of claim 1;

a communication module configured to receive updated consumer information; and

a mounting component suitable for attaching the consumer information display panel to a curved support surface.

55. The consumer information display panel of claim 54, further comprising a consumer interchange interface configured to receive information from a user.

56. A method of manufacturing a first device, said method comprising:

obtaining a first flexible substrate comprising a first glass substrate material; and

disposing a first organic light emitting device over the first flexible substrate, the first organic light emitting device comprising a first emissive layer having a first phosphorescent emissive material;

wherein the first flexible substrate has a thickness of not more than 300 μ

m; and

wherein the first glass substrate material has a flexural rigidity of 10<sup>−

1</sup> Nm to 10<sup>−

6</sup> Nm and a water vapor transmission rate of not more than 10<sup>−

6</sup> g per square meter per day.

57. The method of claim 56, further comprising maintaining the first flexible substrate in a planar configuration while the step of disposing the first organic light emitting device over the first flexible substrate is performed.

58. The method of claim 57, further comprising applying a tension to the first flexible substrate to maintain the first flexible substrate in the planar configuration.

59. The method of claim 57, wherein at least a portion of the first organic light emitting device is deposited via a roll to roll process, and the roller design is supported by the flexural rigidity of the first flexible substrate.

60. A portable data communication device having a flexible OLED display panel, the flexible OLED panel comprising:

a first flexible glass substrate comprising a first glass substrate material;

a second flexible glass substrate;

an OLED device disposed between the first flexible glass substrate and the second flexible glass substrate;

wherein the first flexible substrate has a thickness of not more than 300 μ

m; and

wherein the first glass substrate material has a flexural rigidity of 10<sup>−

1</sup> Nm to 10<sup>−

6</sup> Nm and a water vapor transmission rate of not more than 10<sup>−

6</sup> g per square meter per day.

61. The portable data communication device of claim 60, wherein the second glass substrate material is the same material as the first glass substrate material.

62. The portable data communication device of claim 60, wherein the second glass substrate material has a flexural rigidity of 10⁻

1 Nm to 10<sup>−

6</sup> Nm and a water vapor transmission rate of not more than 10<sup>−

6</sup> g per square meter per day.

63. The portable data communication device of claim 60, wherein the first glass substrate material has a refractive index of not more than 1.5.

64. The portable data communication device of claim 60, wherein the first glass substrate material has a glass transition temperature of at least 300°

C.