Multilayer film for encapsulating oxygen and/or moisture sensitive electronic devices

• US 9,799,854 B2
• Filed: 12/13/2013
• Issued: 10/24/2017
• Est. Priority Date: 04/09/2008
• Status: Active Grant

• Current Assignee: Agency For Science Technology and Research
• Original Assignee: Agency For Science Technology and Research
• Inventors: Ramadas, Senthil Kumar, Chua, Soo Jin, Ke, Lin Karen
• Primary Examiner(s): Murata, Austin
• Application Number:
  US14/106,408
• Publication Number:
  US 20140179040A1
• Time in Patent Office: 1,411 Days
• Field of Search: 427 66
• CPC Class Codes: B32B 2457/206 Organic displays, e.g. OLED
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: H05B 33/04 Sealing arrangements , e.g. against humidity
• CPC Class Codes: H05B 33/10 Apparatus or processes specially adapted to the manufacture of electroluminescent light sources
• CPC Class Codes: H10K 2102/331 Nanoparticles used in non-emissive layers, e.g. in packaging layer
• CPC Class Codes: H10K 30/88 Passivation; Containers; Encapsulations
• CPC Class Codes: H10K 50/841 Self-supporting sealing arrangements
• CPC Class Codes: H10K 50/8445 multilayered coatings having a repetitive structure, e.g. having multiple organic-inorganic bilayers
• CPC Class Codes: H10K 50/846 comprising getter material or desiccants
• CPC Class Codes: H10K 50/865 comprising light absorbing layers, e.g. light-blocking layers
• CPC Class Codes: H10K 71/00 Manufacture or treatment specially adapted for the organic devices covered by this subclass
• CPC Class Codes: Y02E 10/549 Organic PV cells
• CPC Class Codes: Y10T 428/24995 Two or more layers
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31507 Of polycarbonate
• CPC Class Codes: Y10T 428/31511 Of epoxy ether
• CPC Class Codes: Y10T 428/31533 Of polythioether
• CPC Class Codes: Y10T 428/3154 Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31551 : Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31663 : As siloxane, silicone or silane
• CPC Class Codes: Y10T 428/31678 : Of metal
• CPC Class Codes: Y10T 428/31721 : Of polyimide
• CPC Class Codes: Y10T 428/31725 : Of polyamide
• CPC Class Codes: Y10T 428/31931 : Polyene monomer-containing
• CPC Class Codes: Y10T 428/31935 : Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31938 : Polymer of monoethylenically unsaturated hydrocarbon

Abstract

The present invention relates to a multilayer barrier film capable of encapsulating a moisture and/or oxygen sensitive electronic or optoelectronic device, the barrier film including at least one nanostructured layer including reactive nanoparticles capable of interacting with moisture and/or oxygen, the reactive nanoparticles being distributed within a polymeric binder, and at least one ultraviolet light neutralizing layer comprising a material capable of absorbing ultraviolet light, thereby limiting the transmission of ultraviolet light through the barrier film.

Claims

1. A method of fabricating an encapsulated electronic device, comprising:

providing a vacuum enclosure,

arranging within the vacuum enclosure a base substrate having arranged thereon an electronic device to be encapsulated, and

forming a multilayer barrier film on the electronic device, the multilayer barrier film capable of encapsulating a moisture and/or oxygen sensitive electronic or optoelectronic device, and comprising;

at least one nanostructured layer comprising reactive nanoparticles capable of interacting with moisture and/or oxygen, and inert nanoparticles which do not interact with moisture and/or oxygen and which are adapted to obstruct the permeation of moisture and/or oxygen, said reactive nanoparticles and inert nanoparticles being distributed within a polymeric binder, and at least one ultraviolet light neutralizing layer comprising a material capable of absorbing ultraviolet light, thereby limiting the transmission of ultraviolet light through the multilayer barrier film on the electronic device, thereby encapsulating the electronic device, wherein forming the multilayer barrier film on the electronic device comprises;

forming a first layer comprising a material capable of absorbing ultraviolet light on the electronic device, the first layer constituting the ultraviolet light neutralizing layer,

mixing reactive nanoparticles capable of interacting with moisture and/or oxygen and inert nanoparticles which do not interact with moisture and/or oxygen and which are adapted to obstruct the permeation of moisture and/or oxygen with a polymerizable compound having at least one polymerizable group to form a nanoparticulate mixture,

applying the nanoparticulate mixture on the first layer formed on the electronic device, and

exposing the nanoparticulate mixture to ultraviolet light to cure the nanoparticulate mixture during which the first layer functions to limit the transmission of the ultraviolet light onto the electronic device, thereby forming a second layer constituting the nanostructured layer on the first layer.

2. The method of claim 1, further comprising the step of forming a secondary encapsulation over the electronic device encapsulated by the multilayer barrier film,

wherein the multilayer film encapsulating the electronic device is contacted with a curable adhesive in an amount sufficient to surround the electronic device encapsulated by the multilayer barrier film,

attaching a cover substrate on the adhesive prior to compressing the adhesive against the electronic device encapsulated by the multilayer barrier film,

mechanically compressing the cover substrate against the adhesive at an elevated temperature, and

curing the adhesive.