Methods and structures for reducing lateral diffusion through cooperative barrier layers

• US 6,664,137 B2
• Filed: 03/29/2001
• Issued: 12/16/2003
• Est. Priority Date: 03/29/2001
• Status: Expired due to Term

• Current Assignee: Universal Display Corporation
• Original Assignee: Universal Display Corporation
• Inventors: Weaver, Michael Stuart
• Primary Examiner(s): Seidleck, James J.
• Assistant Examiner(s): Ribar, Travis B
• Application Number:
  US09/820,540
• Publication Number:
  US 20020140347A1
• Time in Patent Office: 992 Days
• Field of Search: 428/119, 428/174, 428/179, 428/412, 428/421, 428/446, 428/448, 428/451, 428/473.5, 428/480, 428/500, 428/521, 428/523, 428/704, 438/26, 438/28, 438/125, 438/126, 438/127
• US Class Current: 438/125
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H10K 30/88 Passivation; Containers; Encapsulations
• CPC Class Codes: H10K 39/601 Assemblies of multiple devices comprising at least one organic radiation-sensitive element
• CPC Class Codes: H10K 50/8445 multilayered coatings having a repetitive structure, e.g. having multiple organic-inorganic bilayers
• CPC Class Codes: H10K 77/111 Flexible substrates
• CPC Class Codes: Y02E 10/549 Organic PV cells
• CPC Class Codes: Y10T 428/24174 including sheet or component perpendicular to plane of web or sheet
• CPC Class Codes: Y10T 428/24628 Nonplanar uniform thickness material
• CPC Class Codes: Y10T 428/24669 Aligned or parallel nonplanarities
• CPC Class Codes: Y10T 428/31507 Of polycarbonate
• CPC Class Codes: Y10T 428/3154 Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31667 Next to addition polymer from unsaturated monomers, or aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31721 Of polyimide
• CPC Class Codes: Y10T 428/31786 Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31855 Of addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31931 Polyene monomer-containing
• CPC Class Codes: Y10T 428/31938 Polymer of monoethylenically unsaturated hydrocarbon

Abstract

A covered substrate is described, which comprises: (a) a flexible substrate layer; and (b) a plurality of cooperative barrier layers disposed on the substrate layer. The plurality of cooperative barrier layers further comprise one or more planarizing layers and one or more high-density layers. Moreover, at least one high-density layer is disposed over at least one planarizing layer in a manner such that the at least one high-density layer extends to the substrate layer and cooperates with the substrate layer to completely surround the at least one planarizing layer. When combined with an additional barrier region, such covered substrates are effective for enclosing organic optoelectronic devices, such organic light emitting diodes, organic electrochromic displays, organic photovoltaic devices and organic thin film transistors. Preferred organic optoelectronic devices are organic light emitting diodes.

Claims

1. A covered substrate comprising:

a flexible substrate layer; and

a plurality of cooperative barrier layers disposed on said substrate layer, said plurality of cooperative barrier layers further comprising a planarizing layer and a high-density layer, wherein said high-density layer is disposed over said planarizing layer in a manner such that said high-density layer extends to said substrate layer and, in conjunction with said substrate layer, completely surrounds said planarizing layer, and wherein said covered substrate is disposed between an organic optoelectronic device and an outside environment.

2. The covered substrate of claim 1, wherein said plurality of cooperative barrier layers comprises two or more planarizing layers and two or more high-density layers, and wherein each overlying cooperative baffler layer that is disposed over one or more underlying cooperative barrier layers extends to the substrate layer in a manner such that said one or more underlying cooperative barrier layers are surrounded by said substrate layer and said each overlying cooperative barrier layer.

3. The covered substrate of claim 1, wherein said cooperative barrier layers comprise an alternating series of two or more planarizing layers and two or more high-density layers.

4. The covered substrate of claim 3, wherein said alternating series comprises 3 to 7 planarizing layers and 3 to 7 high-density layers.

5. The covered substrate of claim 1, wherein planarizing layer comprises a material selected from fluorinated polymers, parylenes, cyclotenes and polyacrylates.

6. The covered substrate of claim 1, wherein said high-density layer comprises a material selected from metal oxides, metal nitrides, metal carbides, metals and metal oxynitrides.

7. The covered substrate of claim 1, wherein said high-density layer comprises a material selected from silicon oxide, silicon nitride, aluminum oxide, indium tin oxide and zinc indium tin oxide.

8. The covered substrate of claim 1, wherein said substrate layer is a polymer substrate layer.

9. The covered substrate of claim 8, wherein said polymer substrate layer comprises one or more polymers selected from a polyester, a polyolefin, a polycarbonate, a polyether, a polyimide and a polyfluorocarbon.

10. The covered substrate of claim 8, wherein said polymer substrate layer comprises one or more polymers selected from a polyethersulphone, a polyarylate, a polyestercarbonate, a polyethylenenaphthalate, a polyethyleneterephthalate, a polyetherimide, a polyacrylate, and a polynorbornene.

11. The covered substrate of claim 8, wherein said polymer substrate layer ranges from 75 to 625 microns in thickness.

12. The covered substrate of claim 1, wherein said organic optoelectronic device is selected from an organic light emitting diode, an organic electrochromic display, an organic photovoltaic device and an organic thin film transistor.

13. The covered substrate of claim 1, wherein said organic optoelectronic device is an organic light emitting diode.