EP3113947A1

EP3113947A1 - Roll stock for a submicrometer layer or a roll stock with a submicrometer layer on a flexible backing, and use thereof

Info

Publication number: EP3113947A1
Application number: EP15708224.9A
Authority: EP
Inventors: Jules Fischer
Original assignee: Fofitec AG
Current assignee: Fofitec AG
Priority date: 2014-03-07
Filing date: 2015-03-06
Publication date: 2017-01-11
Also published as: WO2015132410A1; CH709370A1

Abstract

The invention relates to a roll stock which is suitable for a submicrometer layer (5) or which is already provided with a submicrometer layer on a flexible backing, comprising a backing web (1) which forms the backing and which is rolled up on itself with an intermediate layer. The intermediate layer comprises an auxiliary backing web (3) which is provided with a first adhesive layer (2) on one side and a second adhesive layer (4) on the other side. The first adhesive layer (2) is in contact with the rear face or a rear-face coating of the backing web (1) in a nonpermanently adhesive manner. The second adhesive layer (4) is in contact with the front face or a front-face coating or a submicrometer layer (5) which is already provided on the coating in a nonpermanently adhesive manner, and the second adhesive layer has a lower hardness than the backing web (1) in order to pad a submicrometer layer. The roll stock is usable in particular in roller-to-roller methods.

Description

Roll material for or with a sub-micron layer on a flexible support and uses thereof

Technical area

The invention relates to a Roüenmaterial for or with a Submikrometerschicht on a flexible support with a carrier web forming the carrier web, wherein the carrier web is rolled up with an intermediate layer on itself.

In particular, the sub-micron layer may be one or more of the layers used to construct light-active or light-sensitive electronic elements based on organic materials, including barrier layers for protecting the organic material against oxygen and moisture. Light-active electronic elements include light-emitting diodes such as OLEDs (Organic Light Emitting Diodes) and photovoltaic cells such as OPVs (Organic Photovoltaic Cells) for the light-sensitive electronic elements.

The invention also relates to uses of such a roll material. State of the art

Light-active electronic elements on flexible carriers ("light emitting display panels") and processes for their production are known, for example, from US 2004/01 35503 A1. As a flexible carrier are transparent plastic films Among other things mentioned polyester, which are provided with a barrier layer to protect the organic materials from moisture and oxygen. The barrier layer consists for example of SiN and is extremely thin with a typical thickness of 5 - 50 nm.

The light-active elements are constructed in several, likewise very thin layers with thicknesses in the nanometer range in the form of so-called stacks on the barrier layer and, in addition to the light-active organic layers, also comprise electrode layers and an outer encapsulation. The conditions are similar in the case of light-sensitive electronic elements.

Methods for producing the thin barrier layer are ALD (Atomic Layer Deposition), which is carried out under vacuum conditions or under protective gas at ambient pressure, target sputtering or PECVD (Plasma Enhanced Chemical Vapor Deposition).

In order to build up the stacks, the flexible supports on rigid glass plates with a smooth surface are temporarily fixed in US 2004/01 35503 A1. By this fixation thickness variations of the layers to be applied should be avoided. As a means for releasable connection with the glass plates, inter alia, a sheet provided with adhesive layers on both sides is mentioned, wherein the two adhesive layers should have different levels of adhesion. The glass plate is bonded to the more adhesive layer and the flexible base to the weaker layer. After the construction of the stacks or at least individual layers thereof in a so-called "film forming step ^" the detached flexible support from the glass plates and returned the glass plates for re-use in the process. With regard to the thin barrier layer, it is mentioned that it can be applied in a roll-to-roll process.

In a publication of the Frauenhofer Research Institution For Organics, Materials and Electronic Devices COM EDD entitled Roll-to-Roll Line For Organic LED And Solar Cells -

(http://www.comedd.fraunhofer.de/de/comedd/ jcr content / contentPar / lin klist / linklistPar / download / file.res / r2 re.pdf) - is also a roll-to-roll method for applying Submikrometerschichten described by such cells to a carrier webs, wherein the web is unwound from a first reel, on which it is rolled up together with the interleaving or liner designated ^¬ Neten liner on itself. The intermediate layer is removed prior to applying the Submikrometerschichten on the carrier web and rolled up separately. After application of the Submikrometerschichten the carrier web is probably rolled up to protect these layers with an unrolled from another roll and fed to it intermediate layer on a second roll on itself.

The publication also mentions processes under vacuum conditions as well as under inert gas atmospheres for application of submicrometer layers. Presentation of the invention

The invention has as its object to provide a roll material of the type mentioned, by which an improved protection of the existing Submik- rometerschicht is obtained, which offers more favorable conditions for the application and the quality of an applied Submikrometerschicht in roll-to-roll process and which in such processes without removing an intermediate layer and supplying a further intermediate layer manages. This object is achieved by a roll material according to claim 1.

The roll material according to the invention is accordingly characterized in that the intermediate layer comprises an auxiliary carrier web which is provided on its one side with a first adhesive layer and on its other side with a second adhesive layer, wherein the first adhesive layer with the back or a back coating of the carrier web not in permanent contact with the second adhesive layer is non-permanently in contact with the front or a front side coating of the carrier web or with an already existing submicrometer layer, and wherein the second adhesive layer for cushioning one or the sub-micron layer has a lower hardness as the carrier web has.

With regard to the uses of the roll material according to the invention, the object of the invention is to remove any contamination of the carrier web under at least one layer of its front or back coating, in particular under a Submikrometerschicht to avoid. This is achieved by the features of claim 1 1.

According to the invention, this roll material is therefore used in a roll-to-roll process, wherein the roll material is unrolled from a first roll, wherein the carrier sheet of the rolled roll material is in common passage with the auxiliary carrier sheet through at least one processing station having a front and / or back coating and / or a Submikrometerschicht and / or provided with transverse perforations and / or with laterally projecting tabs or indentations, and wherein the thus processed roll material is then rolled up again on a second roll.

In the case of the roll material according to the invention, a submicrometer layer, which may already be present on the carrier web, is covered by the second adhesive layer without gap and thus optimally protected against external influences. The inventive roll material can be stored and transported without further protective measures for its further processing.

Due to the softer, second adhesive layer, the sub-micron layer on the harder carrier web is also padded. Thus, for example, a speck of dust on the surface of the submicrometer layer, which would be capable of damaging the submicrometer layer under the pressure prevailing on the roll, can be resiliently received by the softer second adhesive layer, thus avoiding damage to the submicrometer layer. With regard to a submicrometer layer still to be applied on the carrier layer in the context of a roll-to-roll use according to the invention, the roll material according to the invention offers the advantage that during unrolling and subsequent detachment of the second adhesive layer from the surface to be coated, it is cleaned , Any impurities, especially again dust grains, adhere to the second adhesive layer usually namely stronger than on the surface to be coated and are taken along with the detachment of the second adhesive layer of this and removed. As a result, the submicrometer layer still to be applied is not applied via the impurities, which in the case of dust grains can certainly have dimensions several times greater than the thickness of the submicrometer layer to be applied. By contrast, the fact that the same impurities then come into contact with the freshly applied submicrometer layer during rewinding is still less critical because they are then padded by the softer second adhesive layer as described.

In the use according to the invention, the carrier web and the auxiliary carrier web are themselves connected to each other as they pass through a processing station for applying, for example, a sub-micron layer. Removal of a first auxiliary carrier web and the supply of a second auxiliary carrier web as an intermediate layer as in the prior art is eliminated. The integrated carrying the auxiliary carrier web is only possible through their bonding with the carrier web and would not be possible with only loosely-lanes for non ^¬ avoidable, to wrinkles on the second roll leading Längsverschiebun ^¬ gen. The roll material according to the invention can be used in a simple embodiment with only the carrier web, the auxiliary carrier web, the two adhesive layers and a barrier layer as sub-micron layer, for example as starting material for a process according to US 2004/01 35503 A1. By already containing the flexible carrier web forming the transparent carrier web and provided with the adhesive layers, flexible auxiliary carrier web already connected, eliminates an optionally difficult to perform, separate handling for connecting portions of the carrier and the auxiliary carrier web.

Preferred embodiments of the roll material according to the invention are specified in claims 2-11 and the uses according to the invention are described in claims 1- 3-15.

Thereafter, the carrier web may be a plastic film, in particular a polyester film, or a film of PEN (Polyethlennaphthalat) or a polycarbonate film. Also suitable would be a nanopaper.

Especially for applications in OLEDs or OPVs, the carrier web is preferably transparent and / or light-scattering. Here, nanopapers are of the kind as in Zhiqiang Fang et al. "Novel Nanostructured Paper with Ultra-High Transparency and Ultra-High Haze for Solar Cells", Nano Letters, Just Accepted Manuscript, Publication Date (Web): 27 Dec. 201 3 describe a particularly high transparency of about 96% with simultaneously high haze of about 60%. The thickness of the carrier web can be selected in the range 50-200 μm, preferably in the range 75-1 25 μΐΎΊ.

The auxiliary carrier web can be: a plastic film, in particular again a polyester film, or a fleece or a woven fabric, in particular each of carbon fibers, or a metal foil, in particular of aluminum or strip steel, and / or a thickness in the range 1 2 m-1 00 m exhibit.

With regard to the further layers and the application, the materials used for the carrier web and the auxiliary carrier web should be capable of being subjected to a temperature of at least 90 ° C.

Compared with the carrier web or its at least one coating, the adhesive forces of both adhesive layers should each be less than in relation to the auxiliary carrier web and set so that a 50 mm wide strip of the carrier web with a peel force of 0.05 N - 1 0 N, preferably of 0. 1 N - 5 N and further preferably from 1 - 2 N, at an angle of 1 80 ° detach from them.

In principle, the adhesive forces of both adhesive layers with respect to the carrier web or its at least one coating can be substantially the same size. For both adhesive layers, the same adhesive can be used with advantage, which also allows the use of a nonwoven or fabric embedded in the adhesive as an auxiliary carrier web.

Even with the same adhesive forces, the roll material according to the invention can be used as a flexible support, for example in a process according to US 2004/01 35503 A1, wherein the flexible support after the "film-forming step", as has surprisingly been found, nevertheless of the second adhesive layer can detach without causing a detachment of the first adhesive layer of the glass plate. Thereafter, the remaining on the glass plate portion of the auxiliary carrier web can be deducted from this, wherein the surface of the glass plate for a subsequent reuse with advantage at the same time still cleaned. The same adhesive forces even facilitate the maximization of the fixation of the flexible support on the glass plate, since at different adhesive forces the weaker would determine the maximum possible bond strength. With the same adhesive forces one gains thereby leeway with regard to the adjustment of the adhesive forces.

The second adhesive layer, but preferably also the first adhesive layer, may further have at least one of the following properties: a hardness which is lower than the carrier web by a factor of at least 1 .5 times, preferably at least 2.0 times lower; a thickness of 5 - 20 μιη; it is a PSA (Pressure Sensitive Adhesive) adhesive; it forms without the use of aqueous or organic solvents, chemically, in particular by UV or electron beam, fully cured solid state system; it is temperature resistant up to at least 90 ° C; is made of a hotmelt PSA coatable at temperatures below 50 ° C; it is an extruded plastic film made by blending with sticky tacky or blended resins; it is mixed with adsorbers such as activated carbon; It is mixed with water- and / or oil-binding absorbers.

The term "hardness" used above for the characterization of the carrier web and at least the second adhesive layer is to be understood in the sense of the following, so-called "Hardness Identification ^" test derived from ISO NF 281 5-2005: In this test, a hardened, disk-shaped steel knife is involved a diameter of 50 mm, whose outer edge as a cutting edge with a trapped by the two cutting edges cutting angle of 65 ° under load of 800g weight for 5 sec at right angles to the surface of the material one whose hardness is to be determined. The Length of the resulting in the surface Eindringspur is then used as a measure of hardness. The longer the indenting track, the softer the material or its surface.

In such a test, for example, resulted in a polyester film with 1 00 μιτι thickness, as would be suitable as a carrier layer in the context of the present invention, a length of Eindringspur of 1 mm. In a softer adhesive layer with 1 μιτι thickness thickness on a polyester film with 50 μιτι thickness, as would be suitable at least for the second adhesive layer and the auxiliary carrier web in the present invention, the length of the indenting track contrast was 2.25 mm. Accordingly, in the context of the invention, the tested adhesive layer would have a hardness 2.25 times lower than the tested 100 μm polyester film.

A high softness or low hardness is favorable for the described padding effect. A high softness or low hardness can be achieved inter alia by a relatively large thickness of the adhesive layer. As the thickness increases, adhesive layers regularly but also develop increasing adhesive forces, which according to the above information should be rather low in order to ensure the detachability described. The adhesive forces must also be lower than the cohesion within the adhesive layers, so that the detachment takes place without residue. Thick adhesive layers also show a certain flow behavior, which would also be rather disadvantageous here. At least up to an adhesive layer thickness of 20 μιτι relevant to the invention properties can be realized. For roll-to-roll use according to the invention, at least one of the two adhesive layers must be repositionable at least once. In the case of the mentioned low adhesive forces, non-permanently adhering adhesive layers of the type considered usually have this property. An additional multiple repositionability of both adhesive layers is moreover preferred with regard to the application of several layers in multiple passes and in general to a reusability of the intermediate layer of auxiliary carrier web and the two adhesive layers.

The first and / or the second adhesive layer could also be layers made simultaneously with the auxiliary carrier web in a coextrusion process.

Technologies could also be used for the first and / or the second adhesive layer, as described in Mengüg Y et al. "Staying sticky: contact self-cleaning of cko-inspired adhesives", J. R. Soc. Interface 201 3 1 205 are described.

Suitable as an intermediate layer and thus the function of the auxiliary carrier web and the two adhesive layers is more than taking, where appropriate, a so-called ^¬ Clingfolie. In this embodiment, there is thus no auxiliary carrier web which is still delimited as a discrete layer with respect to two outer adhesive layers. On the other hand, in the embodiment of a nonwoven or woven fabric embedded in an adhesive, instead of two discrete adhesive layers, effectively only a single adhesive layer is present.

If both adhesive layers are extruded plastic films and of the same material and also for the auxiliary carrier web of this material is used, the intermediate layer consists of only one material. In this case, the extrusion for producing the two adhesive layers could be carried out simultaneously with the auxiliary carrier web by "simple" extrusion. It did not need co-extrusion.

Extrusion is a versatile basic operation of process engineering, distinguishing different types of extrusion, especially with regard to toughness of the material to be extruded, temperature and applied pressure. Suitable for film production for use in the present invention could be extrusion processes in which a relatively liquid mass is poured from a slot die more than is pressed. In this case, for example, a falling curtain could be produced, which solidifies by cooling and / or by independent or externally, in particular by UV light-initiated, crosslinking of reactive components. The mass could also be applied to a rotating roller or even directly onto the carrier web for producing a roll material according to the invention. On the roller or the carrier web, the mass could possibly still be doctored off before it solidifies. Should a differentiation between the layers be desired, this could also be achieved with a relatively liquid composition and the aforementioned technique, wherein for example by means of a slot die simultaneously different materials are supplied so that they do not mix each other as possible. By using so-called cascade nozzles, this can be achieved even better.

As is further preferred, the roller material according to the invention is provided with additional layers compared to its simplest embodiment with only the carrier web, the auxiliary carrier web and the two adhesive layers.

Thus, a front-side coating of the carrier web comprises, in particular, a planarization layer which at least partially compensates its roughness. Namely, the natural surface roughness of plastic films may be a multiple of the layer thickness of sub-micron layers, such as the barrier layer in particular. The planarization layer should therefore have a thickness in the range 1 0-50 μιη. At least for large thickness, it can also be applied only part of the area. Corresponding planarization layers are described, for example, in US 201 1/0250392 A1.

In addition to a barrier layer as a submicrometer layer, the carrier web may comprise at the front side at regular intervals on the barrier layer already partially applied electrode layers and / or light-active or light-sensitive polymer layers up to fully formed stacks of OLEDs, OPVs or the like. On the back side, the carrier web may be provided with a light-outcoupling layer and / or a layer which increases its mechanical resistance, such as its scratch-resistance. As an example of a suitable photocoagulating layer, one may be mentioned from the Mate PixCire ™ from Pixelligent Technologies, Baltimore, Maryland, USA.

Finally, in order to facilitate its subdivision into individual sections or sheets, the roll material according to the invention can be provided with transverse perforations at regular intervals. To facilitate the subdivision or subsequent control of partial area layers on the individual sections or arches, laterally projecting tabs or notches may also be provided in the register with the transverse perforations.

The application of a backside coating can be done in the same way as a front side coating on a roll material according to the invention in a roll-to-roll process by the material from the first roll simply with detachment of the first adhesive layer from the back of the carrier web or one on this already existing coating is unrolled. Here too, the described cleaning effect results with respect to the surface to be coated.

In the case of several layers, these can be applied successively in several roll-to-roll passes, wherein in each case the target roll of the preceding pass can be used directly as the starting roll for the subsequent pass. If the device used reverses the transit Direction allowed the roles between two passes must not even be implemented.

By constructing the roll material according to the invention, it is even possible to carry out a front and back side processing of the carrier web in the same pass from roll-to-roll. This can be achieved simply by the following additional steps:

Delamination of the auxiliary carrier web from the carrier web by detaching one of the adhesive layers from one side of the carrier web at a delamination position,

Guiding the auxiliary carrier web in a loop around one of the rollers, and

Laminating the auxiliary carrier web with the carrier web while bonding the other adhesive layer to the other side of the carrier web at a lamination position upstream of the delamination position in the direction of passage.

With regard to the submicrometer layer sensitive to soiling, it is preferable to carry out the uses according to the invention at least under clean-room conditions or under protective gas. If individual layers according to the prior art have to be applied under vacuum conditions, it is preferable to carry out the entire process according to the invention, including unwinding and unwinding in a vacuum chamber. If a roll material according to the invention is to be produced with transverse perforations and associated grip tabs, it is preferred to punch the transverse perforations and the grip tabs in the same pass from roll-to-roll with the same punching tool. In this way, a possibly advantageous tolerance for the subsequent further processing of the roll material according to the invention between the position of the transverse perforations and the grip tabs can be achieved.

Brief description of the drawings

With reference to the drawings, embodiments for roll material according to the invention as well as production method according to the invention are explained below. In all the schematic drawings show:

1 shows a roll of a rolling material according to the invention;

2 shows upper, carrier web-side layers of a section of a rolling material according to the invention with a special design of the front-side coating;

3 shows upper, carrier web-side layers of a section of a rolling material according to the invention with a special design of the rear-side coating;

Fig. 4 a portion of a roll material according to the invention glued on a glass plate

5 shows a section of a roll material according to the invention in a plan view with transverse perforations;

6 shows a method for applying a barrier layer during the production of a roll material according to the invention; Fig. 7 shows a method for applying a back coating of

Carrier web of a roll material according to the invention;

Fig. 8 shows a method for applying a front and a back

Coatings on the carrier web of a roll material according to the invention in the same pass; and

9 shows a method for applying an electrode layer to a roll material according to the invention.

Ways to carry out the invention

Fig. 1 shows a roll material according to the invention according to a first embodiment. It is multi-layered with a transparent carrier sheet 1, a first adhesive layer 2, an auxiliary carrier sheet 3, and a second adhesive layer 4 in this order. On its front side facing away from the first adhesive layer 2, the carrier web 1 is already provided with a coating 5. The coating 5 is a Submikrometerschicht in the form of a barrier layer against the passage of moisture and oxygen or comprises such a barrier layer, in particular as the uppermost layer. The roll material is rolled up in itself flexibly and without an intermediate layer on itself. The second adhesive layer 4 is characterized in adhesive contact with the front coating 5. The second adhesive ^¬ layer 4, however, is non-permanent adhesive with respect to the coating 5 so that it can be removed without residue from this and the roll material as shown in Fig. 1 from the roll is unrolled. Likewise, the second adhesive layer 2 non-permanently adherent to the back of the carrier web 1, so that, as will be explained later, the carrier web 1 can be detached from this adhesive layer 2 without residue. The adhesion of the two Klebschichen 2 and 4 with respect to the surfaces mentioned is relatively weak and beyond repositionable bar, so that they can be made several times after a replacement, if necessary. With regard to the materials of the various layers, their properties and thicknesses, reference may be made to the values and properties already given above.

As already stated, the tightness of the barrier layer is of crucial importance for the life of light-active or light-sensitive, electronic elements based on organic materials. Even the smallest defects in the barrier layer can lead to premature failure of the elements. The front-side coating 5 is therefore preferably constructed multilayered for this application, as shown in FIG. 2. Below a barrier layer 5. 1, a transparent planarization layer 5.2 is present here. Through this layer, the surface roughness of the carrier web 1 is at least partially compensated and created a smoother pad for the barrier layer 5. 1. A further improvement of the barrier effect is achieved by a second barrier layer 5.3 below the planarization layer 5.2, as shown in the right half of FIG. The second barrier layer 5.3 is coated directly on the rough surface of the carrier web, which is not so favorable for their tightness. Nevertheless, together with the first barrier layer 5.sub.1, the second barrier layer 5.3 contributes to the overall tightness of the layer 5, since any imperfections in the barrier layers 5. 1 and 5.3 are at least statistically significant. shear distribution are usually not in the same place in mutual overlap.

In the case of the roll material of FIG. 2, the back side of the carrier web 1 is uncoated, but here too a coating, which will be referred to below as 6 in its entirety, may be present. 3 shows two examples of advantageous backcoats, wherein the coating 6. 1 shown in the right half of FIG. 3 is a transparent material by which the mechanical resistance, such as the scratch resistance, of the carrier web 1 is increased. The layer 6.2 shown in the left half of FIG. 3 is a transparent, light coupling-out layer, which reduces the light reflection at the interface formed by the rear side of the carrier web 1 by a suitably selected refractive index and / or effects a certain light scattering by its surface structure. The properties mentioned could also be achieved simultaneously by a suitable coating material if, for example, the material is both scratch-resistant and has the desired refractive index.

In the representation of a special embodiment of the front of the carrier web 1 and the representation of roughness is omitted in Fig. 3. In fact, however, the embodiments explained with reference to FIG. 2 could also be present here.

FIG. 4 shows an example of a possible use of roll material according to the invention with the above-described layers 1-5 (including, if appropriate, again the layers 5. 1, 5, 2, 5.3, 6, 6. 1 and / or 6.2). On the barrier layer 5 is a light-active electronic element based on organic materials in the form of an OLED stack 1 1 with an anode layer 1 2, a light-active polymer layer 1 3, a cathode layer 1 4th and an encapsulation 1 5 constructed, it does not depend on the nature and design of the electronic element here. It could also be another or a light-sensitive element.

The gluing of the roll material 1-5 on the glass plate G serves the purpose of its temporary fixation for register-accurate application of the layers 1 2 - 1 5 of the OLED stack 1 first Tolerances in the μηη range must be complied with here as a rule. The means required for this sticking is already integrated in the roll material according to the invention through the auxiliary carrier web 3 and the two adhesive layers 2 and 4.

After the application of the layers 1 2 - 1 5, the portion of the carrier web 1 is detached as a flexible carrier of these layers of the first adhesive layer 2, as illustrated in Fig. 4 by the arrow P 1. The detachment is in this case executed ^¬ that the composite of the auxiliary carrier web 3 with the two adhesive layers 2 and 4 remaining on the glass plate G. Only in a second step is this composite also detached from the glass plate G, as is illustrated in FIG. 4 by the arrow P2. Thereafter, the glass plate G is available for further appropriate use. This sequential detachment is also possible if the same adhesive is used for the two adhesive layers 2 and 4 and the adhesive By virtue of the cooling layer 2, with respect to the rear side of the support 1, the adhesive force of the adhesive layer 4 with respect to the glass plate G is approximately the same.

In the case of a false coating, the section 1 0 can also be completely removed with all layers of the glass plate G, after which it is also immediately available for reuse.

5 shows a longitudinal section of a roll material according to the invention, which is divided by transverse perforations 16 into a plurality of sections designated n-1, n and n + 1. By means of the transverse perforations 16, the individual sections can be easily separated from one another, for example for use according to FIG. 4.

Each of the sections of Fig. 5 is, as also shown, preferably additionally provided with laterally protruding tabs (1 7), which can be produced by punching technically at a straightening of the side edges of the roll material. The tabs 1 7 can be used as grip tabs in the method of FIG. 4 for detaching the portion of the carrier web 1 from the composite of the auxiliary carrier web 3 with the two adhesive layers 2 and 4. For this application, it is advantageous if this composite does not extend into the tabs 1 7 inside. The tabs 1 7 could also be used as markers for a sequential driving of several local layers such as the layers 1 2- 1 5 of the OLED stack 1 1 of FIG. 4 in register on the individual sections. A high precision can be achieved if, on the roll material of Fig. 5, the Querperforationen 1 6 and the handles 1 7 have been punched in the same run from oile-to-roll with the same punch.

With reference to FIGS. 6-9, further uses of roll material according to the invention will now be explained. This is a so-called roll-to-roll process, in which an endless web is unwound from a first roll R 1, rolled up again on a second roll R2 and processed therebetween. On both rollers R 1 and R 2, the continuous web is rolled up on itself without an intermediate layer (interleave).

In the method of FIG. 6, on the first roll 1 there is a roll material according to the invention with the already described layers 1-4, ie with a carrier web 1, a first adhesive layer 2, an auxiliary carrier web 3 and a second adhesive layer 4 in this order , By this material is rolled onto itself without interposition in several turns, at least one turn of the second adhesive layer 4 is in contact with the front side of the Trä ^¬ gerbahn 1 an adjacent turn. In passing through a processing station S 1, a submicrometer layer in the form of a bar ^¬ riereschicht 5 or such a layer is applied to the front of the carrier web 1 in Fig. 6.

Provided that impurities such as in particular dust particles are located on the front of the carrier web to be coated 1, they are taken during the rolling of the roller 1 by the adhesive of the second adhesive layer 4 and thus removed from the Trä ^¬ gerbahn. 1 The front side of the carrier web 1 becomes in this way indirectly cleaned before coating. In Fig. 6, the second adhesive layer 4 is shown loaded with individual dust grains, one of which is denoted by 1 8.

By the endless web in the process of Fig. 6 without interposition in several turns on the roll R2 is rolled back on itself, come the dust grains 1 8 there with the freshly applied, front coating 5 while in contact, but now on the top. They are embedded in and / or supported by the substantially softer in relation to the carrier web 1 and the coating 5, and in relation to the coating 5 also substantially thicker adhesive of the second adhesive layer 4 and thereby can be formed by the coating 5 or in her contained barrier layer do no damage.

In contact with the second adhesive layer 4, the coating 5 on the second roller R2 is also well protected against environmental influences such as in particular against exposure to further dust and can thus be stored and transported, for example, for further processing according to FIG. 4 without additional, at least complex protective measures ,

Contamination of the surface to be coated between the unwinding of the roll 1 and the rolling up on the roll R2 can be ensured, for example, by clean room conditions. If the mentioned ALD process is used under vacuum for applying the coating 5, it is preferable to use the entire process of FIG. 6 including the unrolling of the Roll R 1 and rolling on the roll R2 perform in the same vacuum vessel, whereby contamination between the rollers can also be avoided.

The method of FIG. 6 may be carried out several times in succession, for example, to apply only one barrier layer 5, for example, to apply the layers 5.1 - 5.2 according to FIG. 2. This results in each time with advantage the cleaning effect when rolling from the roll R 1 and the protective effect when rolling on the roll R2. It could be provided for the order of several front-side layers in the same pass also several processing station in series one behind the other between the two rollers R 1 and R2 has this Fig. Shows. Also, several layers could be successively applied by reversing the direction of passage between the rollers R 1 and R 2 without staggering the rollers R 1 and R 2.

In Fig. 7 is located on the roll R 1, an inventive roll material with layers 1-5 corresponding to the material on the roll R2 of Fig. 6. However, this material is now handled so that the back of the carrier web 1 detached from the adhesive layer 2 and is exposed. Only the expressed Win ^¬ tion with the layers 2, 3 and 4 falls in this type of settlement as waste. In the passage through at least one processing station S2, the back of the carrier web can then be coated, for example, with one of the layers 6. 1 or 6. 2 of FIG. 3. The method of Fig. 8 allows the application of a front and a back coating on the carrier web 1 of a roll material corresponding to that on the roll R 1 of Fig. 6 in a single pass. For this purpose, as in FIG. 6, the material is unrolled from the roll R 1, exposing the front side of the carrier web 1, and thereafter provided, for example, with a barrier layer 5 on the front in the passage through a processing station S 1. At a downstream Delaminierposition D, the auxiliary carrier web 3 is separated together with the two adhesive layers 2 and 4 with detachment of the first adhesive layer 2 from the back of the carrier web 1 and guided in a loop around the roller R 1. He is then connected to the already on the front side of the carrier web 1 barrier layer 5 with the second adhesive layer 4 at a lamination position L upstream in the direction of passage of Delaminierposition D. The exposed after Delaminierposition D back of the carrier web 1 is then provided in a processing station S2 with a back coating, for example, according to the coating 6. 1 or 6.2 of Fig. 3. Finally, the roll material coated on both sides is rolled up again on a roll R2.

FIG. 9 also shows how, on a barrier layer 5 of a roll material according to the invention located on the roll R 1, at least one further layer, in particular an electrode layer corresponding to the electrode layer 1 2 of FIG. 4, could be applied over part of its area as it passes through a processing station S3. By repeated passage or in the presence of further processing stations in series, even further layers, not shown in FIG. 8, up to the complete stack of a light-active or light-sensitive electronic element based on organic materials could also be produced. to be brought. The invention is insofar not limited to roll material for light-active or light-sensitive, electronic elements based on organic materials but may also include such elements.

In order to be able to apply the individual layers of these elements in such a process without fixing on a glass plate according to FIG. 4 with the required small tolerances relative to one another, it may be favorable for the auxiliary carrier web 3 to have a dimensionally stable material than a plastic film use. Suitable for this purpose would be, for example, a metal foil, in particular made of aluminum or strip steel.

LIST OF REFERENCE SIGNS

1 carrier web

2 first adhesive layer

3 auxiliary carrier track

4 second adhesive layer

5 front coating / barrier layer

5.1 barrier layer

5.2 Planarization Layer

5.3 second barrier layer

6 back coating

6. 1 scratch-resistant coating

6.2 Light decoupling layer

G glass plate

1 0 roll material section

1 1 OLED stack

1 2 anode layer

1 3 light-active polymer layer

1 4 cathode layer

1 5 encapsulation

1 6 transverse perforations

1 7 tabs

1 8 dust grains

R 1 first roll

R2 second role

S 1, S2, S3 processing stations

D Delamination position

L lamination position

P 1 arrow

P2 arrow

Claims

Patent claims

1. Roll material for or with a submicrometer layer (5) on a flexible carrier with a carrier web (1) forming the carrier, the carrier web (1) being rolled up on itself with an intermediate layer, characterized in that the intermediate layer is an auxiliary carrier web ( 3), which is provided on one side with a first adhesive layer (2) and on its other side with a second adhesive layer (4), the first adhesive layer (2) having the back or a back coating (6; 6.1; 6.2) the carrier web (1) is in non-permanently adhesive contact, the second adhesive layer (4) being with the front or a front- ^side coating (5.

2) the carrier web (1) or a submicrometer layer (5; 5, 1; 5) already present thereon.

3; 1 2; 1 3; 1 4; 1 5) is in non-permanently adhesive contact, and wherein the second adhesive layer (4) for cushioning one or the ^{submicrometer} layer has a lower hardness than the carrier web (1). Roll material according to claim 1, characterized in that the carrier web (1) is a plastic film, in particular a polyester film, a polyethylene naphthalate film or a polycarbonate film or a nanopaper, and / or transparent, and / or light-scattering, and / or by a factor at least 1.5 times, preferably at least 2.0 times, greater hardness than the second adhesive layer (4), and/or a thickness of 50 - 200 μm, preferably 75 - 1 25 pm.

Roll material according to claim 1 or 2, characterized in that the auxiliary carrier web (3) is a plastic film, in particular a polyester film or a fleece or a fabric, in particular made of carbon fibers, or a metal foil, in particular made of aluminum or steel strip, and / or a thickness of 1 2 - 1 00 μιτι.

4. Roll material according to one of claims 1 - 3, characterized in that the adhesive forces of both adhesive layers (2, 4) relative to the carrier web (1), a submicrometer layer (5; 5. 1) present on its front side or one present on its back side Coating (6; 6. 1; 6.2) is each smaller than that of the auxiliary carrier web (3) and is set so that a 50 mm wide strip of the carrier web (1) with a pull-off force of 0.05 N - 1 0 N, preferably 0.1 N - 5 N and more preferably from 1 -2 N, can be detached from them at an angle of 1 80 °.

5. Roll material according to one of claims 1 -4, characterized in that the intermediate layer consists of a uniform material. a hardness that is lower by a factor of at least 1.5 times, preferably at least 2.0 times, than the carrier web (1); a thickness of 5 - 20 μηη; it forms a solid-state system that is completely cured without the use of aqueous or organic solvents, chemically, in particular using UV or electron beams; it is temperature-resistant up to at least 90°; is made from a hot-melt adhesive that can be coated at temperatures below 50°C; it is an extruded plastic film with adjusted tackiness by mixing with tackifying or dulling resins; it is provided with adsorbents such as activated carbon; it is provided with water and/or oil-binding absorbers.

Roll material according to one of claims 1 - 5, characterized in that the intermediate layer consists of a material.

Roll material according to one of claims 1 - 5, characterized in that the front of the carrier web ( 1 ) is provided with a planarization layer ( 5.2 ) that at least partially compensates for its roughness.

Roll material according to one of claims 1 - 6, characterized in that the carrier web (1) has on its front at least one submicrometer layer (5; 5. 1) with at least one of the following properties: it is a barrier layer (5; 5. 1; 5.3) to protect light-active or light-sensitive organic materials from moisture and oxygen; it is a light-active or light-sensitive layer (1 3) based on ^organic materials of a light-active or light-sensitive electronic element (1 1); it is an electrode layer (12; 14) of a light-active or light-sensitive electronic element (11), it has a thickness of 5 - 120 nm.

9. Roll material according to claim 7, characterized in that at least one submicrometer layer (12; 13; 14) is applied over part of the surface of the carrier web (1) at regular intervals.

10. Roll material according to one of claims 1 - 8, characterized in that the carrier web has a back coating (6) which has a light-coupling layer (6.2) and / or a layer that increases the mechanical resistance such as the scratch resistance of the carrier web (1). (6.1) includes.

11. Roll material according to one of claims 1 - 9, characterized in that it is provided at regular intervals with transverse perforations (16) to facilitate its subdivision into sheets (n-1, n, n+1) and / or that it is at regular intervals Distances laterally projecting tabs (17) or notches, which are preferably arranged in register with the transverse perforations (16).

12. Use of a roll material according to one of claims 1 - 10 in a roll-to-roll process, wherein the roll material is unrolled from a first roll (R1), wherein the carrier web (1) of the unrolled roll material passes together with the auxiliary carrier web (3) through at least one processing station (S1; S2; S3; ... Sn) with a front and/or back coating (6; 6.1; 6.2; 5.2) and/or a submicrometer layer (5.1; 5.2; 12;: 13; 14; 15) and/or with transverse perforations (16) and/or with laterally projecting tabs (17) or notches, and this is so The processed roll material is then rolled up again on a second roll (R2).

13. Use according to claim 11, characterized in that the following steps are carried out for the front and back processing of the carrier web (1) in the same pass from the roll of the first roll (R1) to the second roll (R2):

Delaminating the auxiliary carrier web (3) from the carrier web (1) by detaching one of the adhesive layers (2; 4)) from one side of the carrier web (1) at a delamination position (D),

Guide the auxiliary carrier web (3) in a loop around one of the rollers (R1; R2), and

Laminating the auxiliary carrier web (3) with the carrier web (1) while connecting the other adhesive layer (4; 2) to the other side of the carrier web (1) at a laminating position (L) upstream of the delamination position (D) in the direction of travel.

14. Use according to one of claims 11 or 12, characterized in that the unwinding, processing and rolling up of the roll material is carried out under clean room and/or under vacuum conditions.

15. Use according to one of claims 1 - 13, characterized in that transverse perforations (16) and tabs (17) or notches are punched in the same pass from the first roll (R1) to the second roll (R2) with the same punching tool.