Method of fabricating organic light emitting device (OLED) panel of arbitrary shape

• US 9,343,695 B2
• Filed: 08/13/2014
• Issued: 05/17/2016
• Est. Priority Date: 08/13/2014
• Status: Active Grant

• Current Assignee: Universal Display Corporation
• Original Assignee: Universal Display Corporation
• Inventors: Hack, Michael, Ma, Ruiqing, Krall, Emory, Quinn, William E.
• Primary Examiner(s): LE, DUNG ANH
• Application Number:
  US14/458,275
• Publication Number:
  US 20160049608A1
• Time in Patent Office: 643 Days
• Field of Search: 257/40, 257/43, 257/89, 257/98, 438/48
• US Class Current: 1/1
• CPC Class Codes: H10K 2101/40 Interrelation of parameters between multiple constituent active layers or sublayers, e.g. HOMO values in adjacent layers
• CPC Class Codes: H10K 2102/302 of OLED structures
• CPC Class Codes: H10K 2102/311 Flexible OLED
• CPC Class Codes: H10K 2102/341 Short-circuit prevention
• CPC Class Codes: H10K 50/11 characterised by the electroluminescent [EL] layers
• CPC Class Codes: H10K 50/13 comprising stacked EL layers within one EL unit
• CPC Class Codes: H10K 50/80 Constructional details
• CPC Class Codes: H10K 50/805 Electrodes
• CPC Class Codes: H10K 50/81 Anodes
• CPC Class Codes: H10K 50/813 characterised by their shape
• CPC Class Codes: H10K 50/814 combined with auxiliary electrodes, e.g. ITO layer combined with metal lines
• CPC Class Codes: H10K 50/82 Cathodes
• CPC Class Codes: H10K 50/822 characterised by their shape
• CPC Class Codes: H10K 50/84 Passivation; Containers; Encapsulations
• CPC Class Codes: H10K 50/8426 Peripheral sealing arrangements, e.g. adhesives, sealants
• CPC Class Codes: H10K 50/844 Encapsulations
• CPC Class Codes: H10K 59/84 Parallel electrical configurations of multiple OLEDs
• CPC Class Codes: H10K 59/86 Series electrical configurations of multiple OLEDs
• CPC Class Codes: H10K 71/00 Manufacture or treatment specially adapted for the organic devices covered by this subclass
• CPC Class Codes: H10K 71/851 Division of substrate
• 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

OLED panels and techniques for fabricating OLED panels are provided. Multiple cuts may be made in an OLED panel to define a desired shape, as well as the location and shape of external electrical contacts. The panel may be encapsulated before or after being cut to a desired shape, allowing for greater flexibility and efficiency during manufacture.

Claims

1. A method of fabricating an organic light emitting device (OLED) panel having an arbitrary shape, the method comprising:

obtaining a first OLED panel comprising a plurality of layers, the layers including a substrate, an anode, a cathode, and an emissive organic stack;

making a first cut in the first OLED panel on a first shape outline, wherein the first cut does not extend through at least one layer of the first OLED panel; and

making a second cut in the first OLED panel, wherein the second cut extends through each of the plurality of layers of the first OLED panel.

2. The method of claim 1, further comprising encapsulating the first OLED panel.

3. The method of claim 2, wherein the step of encapsulating the OLED panel is performed subsequent to the steps of making the first cut and making the second cut.

4. The method of claim 2, wherein the step of encapsulating the OLED panel is performed prior to the steps of making the first cut and making the second cut.

5. The method of claim 4, further comprising depositing a metal layer over an exposed edge of the OLED panel.

6. The method of claim 1, wherein the first cut forms a first externally-accessible electrical connection.

7. The method of claim 1, wherein the second cut is performed prior to the first cut.

8. The method of claim 1, wherein the first cut and the second cut are performed at least partially concurrently.

9. The method of claim 1, wherein the first cut extends through the cathode, but does not extend through at least a part of the emissive organic stack.

10. The method of claim 1, wherein the second cut defines an anode bus connection in the OLED panel.

11. The method of claim 1, further comprising:

obtaining a second OLED panel comprising a plurality of layers, the layers including a substrate, an anode, a cathode, and an emissive organic stack;

making a first cut in the second OLED panel on a second shape outline different than the first shape outline, wherein the second cut does not extend through at least one layer of the second OLED panel; and

making a second cut in the second OLED panel, wherein the second cut extends through each of the plurality of layers of the second OLED panel.

12. The method of claim 11, wherein the first OLED panel and the second OLED panel are disposed on a common substrate.

13. The method of claim 11, wherein the first cut in the first OLED panel and the first cut in the second OLED panel are made with the same cutting mechanism.

14. The method of claim 1, wherein each of the first and second cuts is made with a laser ablation process.

15. The method of claim 1, further comprising sealing an edge of the OLED panel along the second cut.

16. The method of claim 1, wherein the substrate comprises a polymer cast on glass, the method further comprising, subsequent to making the first cut and the second cut, removing the polymer and the OLED from the glass to obtain a the OLED panel.

17. An OLED panel fabricated according to the method of claim 1.