WO2009136305A1 - Reelable oled curtain - Google Patents

Reelable oled curtain Download PDF

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Publication number
WO2009136305A1
WO2009136305A1 PCT/IB2009/051687 IB2009051687W WO2009136305A1 WO 2009136305 A1 WO2009136305 A1 WO 2009136305A1 IB 2009051687 W IB2009051687 W IB 2009051687W WO 2009136305 A1 WO2009136305 A1 WO 2009136305A1
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WO
WIPO (PCT)
Prior art keywords
light
layer
emitting
flexible
organic
Prior art date
Application number
PCT/IB2009/051687
Other languages
French (fr)
Inventor
Peter Van De Weijer
Herbert Lifka
Cristina Tanase
Coen A. Verschuren
Original Assignee
Koninklijke Philips Electronics N.V.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
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Application filed by Koninklijke Philips Electronics N.V. filed Critical Koninklijke Philips Electronics N.V.
Publication of WO2009136305A1 publication Critical patent/WO2009136305A1/en

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    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10KORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K50/00Organic light-emitting devices
    • H10K50/80Constructional details
    • H10K50/84Passivation; Containers; Encapsulations
    • H10K50/844Encapsulations
    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10KORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K2102/00Constructional details relating to the organic devices covered by this subclass
    • H10K2102/301Details of OLEDs
    • H10K2102/311Flexible OLED
    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10KORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K30/00Organic devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation
    • H10K30/80Constructional details
    • H10K30/88Passivation; Containers; Encapsulations

Definitions

  • the present invention relates to organic light-emitting or light-absorbing devices, and more particularly to a reelable organic light-emitting or light-absorbing device for large-area applications and a method of manufacturing such a device.
  • a traditional OLED typically comprises a stack of organic layers 2 which are sandwiched between an anode 3 and a cathode 4.
  • an electrical contact 9 is electrically connected to the cathode 4.
  • the stack of organic layers 2 comprises at least a light-emitting layer and is usually combined with one or more charge carrier and/or charge injection layers.
  • ITO indium tin oxide
  • the anode 3 may be patterned in a desired way, e.g. as a pixel matrix.
  • a metal having a low work function and covered with a protective metal like aluminum or a metal halide covered with aluminum is deposited on the stack of organic layers 2 to act as the cathode 4.
  • a voltage is applied across the stack of organic layers 2, light is produced in the light-emitting layer. The light can escape through the transparent anode 3 and the transparent substrate 5.
  • An OLED needs encapsulation by a cover 6 to prevent degradation through interaction with the ambient atmosphere. Water vapor is considered a harmful component for the OLED. Even when the OLED is provided with an encapsulating cover 6, a getter 7 is normally inserted in the cavity between the cover 6 and the substrate 5 to remove water penetrating through glue 8 that is used as an edge sealant for the cover 6.
  • both the substrate 5 and the encapsulating cover 6 are rigid, e.g. in the form of a glass substrate and a glass cover. Both the substrate and the cover are made in flexible materials in the case of flexible OLEDs.
  • a plastic foil may be used as a substrate for the purpose of providing flexibility. When plastic foils are used as the substrate, these must be combined with a barrier layer to prevent water diffusion through the substrate. Such a barrier layer is also a prerequisite for encapsulation as an alternative to the glass cover of the traditional OLED. Sugimoto et.
  • OLED is an organic electronic device.
  • OLEDs typically comprise a plurality of organic layers arranged between two transparent electrodes, amongst which organic layers at least one layer is optoelectronically active, e.g. light- emitting as in the previous description.
  • the light-emitting layer is an organic material that is capable of emitting light in response to receiving a voltage in a light-emitting mode.
  • the optoelectronically active layer in an organic electronic device can also be used in a photovoltaic state, i.e. a photovoltaic layer.
  • a photovoltaic layer generates a current and/or a voltage when receiving and absorbing light in a photovoltaic mode.
  • applying a voltage across the electrodes in the light-emitting mode causes light to be emitted from the light-emitting organic layer, and shining light on the device in the photovoltaic mode results in a current and/or voltage generated at the electrodes.
  • Well-known organic electronic devices that utilize the photovoltaic mode are solar cells.
  • Very thin flexible OLEDs open up the possibility for attractive foldable display devices, and the companies in the field of display technology are racing to provide the best foldable displays.
  • very thin foldable organic light-absorbing devices i.e. with the organic electronic device being used in the photovoltaic state, open up new applications.
  • Not many prior art solutions focus on flexible large-area light-emitting or light-absorbing applications. These devices may be used, for example, to provide curved objects with a light- emitting surface or, if flexibility is sufficient, create reelable OLEDs for large-area lighting applications.
  • This object is achieved by an organic light-emitting or light-absorbing device and a method of manufacturing an organic light-emitting or light-absorbing device according to the present invention as defined in the independent claims 1 and 14.
  • an organic light-emitting or light-absorbing device comprising a light unit, which comprises a flexible bottom layer having at least one first barrier layer.
  • a bottom electrode is provided on top of the at least one first barrier layer.
  • an organic layer stack is deposited on top of the bottom electrode.
  • the organic layer stack is designed to emit or absorb light.
  • a top electrode is arranged on top of the organic layer stack, and at least one second barrier layer is provided on top of the top electrode.
  • the device further comprises a first flexible protection layer and a second flexible protection layer. The first flexible protection layer and the second flexible protection layer are arranged to encase the light unit, such that a large area support structure is provided for the device and such that the device is reelable.
  • a strong organic light-emitting or light-absorbing device suitable for large-area applications.
  • Providing the flexible light unit, which by itself is extremely flexible, with protection layers renders it possible to arrange the device in an application that is exposed to mechanical stresses during use.
  • the unique selling points of OLEDs for large-area lighting purposes are beyond dispute in the lighting community. Since the OLED intrinsically is a large-area device that provides diffuse, homogenous light which is pleasant to look at, i.e. which provides low contrast and saturated colors, these devices are very attractive for use in large-area applications. This is in sharp contrast to its counterpart, the inorganic LED, which is a high-brightness point source.
  • inorganic LEDs all kind of "tricks" have to be played in order to obtain large-area light sources.
  • Other benefits of OLEDs are their free form factor, transparency, flexibility, ultrathin dimensions, and low- cost manufacture.
  • the current invention relates to flexibility and a way to adjust this flexibility to the specific demands of the application.
  • the thickness of the first flexible protection layer and the second flexible protection layer is chosen in a range between 1 and 5000 micrometers.
  • the flexible bottom layer is a plastic foil.
  • the flexible bottom layer is a metal foil.
  • the top electrode is at least semi-transparent, thus providing an at least semi transparent OLED.
  • a static pattern is applied in at least one layer of the device, such that an attractive pattern or static information is integrated in the large-area lighting application.
  • a dynamic pattern is applied in at least one layer, providing the ability to apply dynamic patterns and/or information in the large-area light-emitting or light-absorbing application.
  • the device is provided with pixels, and each pixel contains control electronics.
  • the device is utilized as wallpaper.
  • a spatial partition device comprising a reeling device and an organic light-emitting or light-absorbing device according to the present invention, which device is in engagement with the reeling device at a first end. Furthermore, the organic light-emitting or light-absorbing device is arranged such that it can be reeled onto the reeling device.
  • a space partition device is provided which can advantageously assume three different states. This will be described for the organic light-emitting or light-absorbing device when used in the light-emitting state: First, the OLED may be fully reeled up onto the reeling device, in which state no space partition is achieved. Second, when the OLED is reeled out and in its off-state, the OLED partitions the space of the room.
  • the space partition device further comprises an additional organic light-emitting or light-absorbing device according to the present invention.
  • the bottom layer of the additional organic light emitting or light absorbing device is arranged facing the bottom substrate layer of the organic light emitting or light absorbing device.
  • the organic light-emitting or light-absorbing device and the additional organic light-emitting or light-absorbing device emit light of respective predetermined colors in the light-emitting state.
  • the space partition device is utilized as a roller blind.
  • a method of manufacturing an OLED comprising the steps of: providing a support substrate, - arranging a light unit by on the support substrate: providing a flexible bottom layer on the support substrate, applying at least one first barrier layer to the flexible bottom layer, providing a bottom electrode on the at least one first barrier layer, depositing an organic layer stack on top of the bottom electrode, - providing a top electrode on top of the organic layer stack, and providing at least one second barrier layer on top of the top electrode, providing a first flexible protection layer on the second barrier layer, removing the light unit from the support substrate, providing a second flexible protection layer on the flexible bottom layer.
  • the first protection layer and the second protection layer provide a large-area support structure such that the device is reelable.
  • the thicknesses of the flexible protection layers are chosen in a range between 1 and 5000 micrometer.
  • Fig. 1 is a cross-sectional view of a typical prior art organic light-emitting device
  • Fig. 2 is a cross-sectional view of an embodiment of an organic light-emitting or light-absorbing device according to the present invention
  • Figs. 3 a) to i) are illustrations presenting cross-sectional views of an organic light-emitting or light-absorbing device being manufactured in accordance with an embodiment of a method of manufacturing an organic light-emitting or light-absorbing device according to the present invention.
  • Figs. 4 a) to d) illustrate space partition devices according to embodiments of the present invention. DESCRIPTION OF PREFERRED EMBODIMENTS
  • the present inventive concept is suitable for organic light-emitting or light- absorbing devices.
  • An organic light-emitting device is described for the sake of simplicity in the following embodiments of a device according to the present invention, but the concept is also suitable for an inorganic light-absorbing device.
  • the OLED 20 comprises a light unit 30 (Figs. 3 h and i clarify the light unit 30).
  • the light unit is arranged having a flexible bottom layer 24 on which at least one first barrier layer 27 is deposited.
  • the first barrier layer 27 may comprise a number of thin- film barrier layers that are stacked so as to form a protection against moisture or gas.
  • the flexible bottom layer 24 in this exemplifying embodiment is arranged as a polyimide film, i.e. a plastic foil. Any other suitable flexible polymeric material, such as e.g. polyethylene terephthalate (PET) and polypropylene, may alternatively serve as the flexible bottom layer for the device.
  • PET polyethylene terephthalate
  • polypropylene any other suitable flexible polymeric material, such as e.g. polyethylene terephthalate (PET) and polypropylene, may alternatively serve as the flexible bottom layer for the device.
  • a conductive layer is provided on top of the first barrier layer 27 so as to form a bottom electrode 22, i.e. an anode.
  • the bottom electrode 22 is transparent.
  • a well-known method of providing a transparent, conducting anode layer is to deposit a thin layer of Indium Tin Oxide, ITO.
  • an organic layer stack 21 is arranged on top of the transparent bottom electrode 22.
  • the organic layer stack 21 is designed to emit light and comprises light- emitting layers and one or more charge carrier and/or charge injection layers, which are not explicitly shown in the figures.
  • the organic layer stack 21 can be designed to emit light of a predetermined color.
  • a top electrode 23 is arranged on the organic layer stack 21.
  • a second barrier layer 28 is arranged on the top electrode 23.
  • the second barrier layer 28 may comprise a plurality of thin-film layers which are designed to keep water and atmospheric gases away from the sensitive top electrode and the organic layers of the organic layer stack 21.
  • the light unit is arranged so as to have an electrical contact 26 for powering the light unit.
  • the OLED 20 is further arranged such that the light unit 30 is provided with a large-area support structure comprising a first flexible protection layer 35 and a second flexible protection layer 25.
  • the second flexible protection layer 25 is arranged at the flexible bottom layer 24 and the first flexible protection layer 35 is arranged at the second barrier layer 28.
  • the first flexible protection layer 35 and the second flexible protection layer 25 are arranged at the light unit 30 and act as a large-area protection structure for mechanical protection of the device.
  • the thickness of the first flexible protection layer 35 and the second flexible protection layer 25 is typically chosen in the range from 1 to 5000 ⁇ m.
  • the thickness of these flexible protection layers 25 and 35 is preferably tuned to match the radius of curvature for a specific application.
  • the large-area support structure which is formed by laminating of the light unit 30 with the protection layers 25, 35 is so flexible that the OLED 20 is reelable.
  • the protection layers 25, 35 are arranged on the light unit 30 by spin-coating of the first protection layer 35 and the second protection layer 25 onto the light unit.
  • the top electrode 23 is at least semi-transparent. This way the light emitted from the organic layer stack 21 can exit the OLED 20 through the lower side, i.e. passing through the transparent bottom electrode 22 and the at least semi-transparent top electrode 23.
  • At least semi- transparent electrodes can be achieved by various techniques, see e.g. US Patent 6885149 or US Patent 5739545.
  • a method of manufacturing an OLED which will now be described with reference to Figs. 3 a) to i).
  • a rigid carrier i.e. a support substrate 40
  • the support substrate 40 e.g. a standard glass plate, is temporarily used during the manufacturing of the light unit 30 of the OLED 20.
  • the manufacture of the light unit 30 is started by providing a flexible bottom layer 24. This may be done by coating the support substrate 40 with a thin layer of polyimide in a standard spin-coating procedure used in display technology. The polyimide is cured so as to form the flexible bottom layer 24, cf. Fig. 3 b).
  • At least one thin- film first barrier layer 27 is now applied on top of the flexible bottom layer 24.
  • the first barrier layer 27 is provided on the flexible bottom layer 24 to act as a thin-film water barrier.
  • the first barrier layer 27 also helps protect the polyimide film 24 during the remaining processing of the OLED, e.g. during the deposition of the bottom electrode 22 and the organic layer stack 21.
  • a bottom electrode 22 is now arranged on top of the first barrier layer 27 through deposition of a thin ITO-layer by means of e.g. sputtering, or some nano composite printing technique, cf. Fig. 3 d).
  • Other common transparent conductive oxides for transparent electrodes include e.g.
  • the organic layer stack 21 is now processed on top of the bottom elctrode 22, cf. Fig. 3 e). This is followed by providing a top electrode 23 and appopriate contact means 26, cf. Fig. 3 f).
  • At least one second barrier layer 28 is arranged on top of the top electrode 23 to seal the light unit 30, cf. Fig. 3 g).
  • the light unit 30 and the support substrate 40 are separated, cf. Fig. 3 h).
  • a laser release process is used to remove the glass substrate 40.
  • the support substrate 40 may be reused for the manufacture of more light units 30.
  • the resulting light unit 30 can be as thin as 10 ⁇ m and shows extreme flexibility, the radius of curvature being well below 1 cm.
  • Such ultrathin light units with thicknesses down to 10 ⁇ m (which are flexible like e.g. cigarette paper), however, are not practicable for large area applications.
  • the light unit 30 is placed between a first flexible protection layer 35 and a second flexible protection layer 25.
  • These protection layers may be applied by lamination of foils, by spin coating of a layer, or by other deposition techniques.
  • the protection layers provide a large- area support structure for the mechanical protection for the OLED 20.
  • the thicknesses of the protection layers 25, 35 are typically chosen in a range from 1 to 5000 ⁇ m, and the flexibility of the OLED 20 can be tuned to match the radius of curvature for a specific application through adaptiation of the thickness of the protection layers 25, 35 to a suitable value.
  • the first flexible protection layer 35 and the second flexible protection layer 25 are arranged by a standard lamination technique using polyethylene naphthalate (PEN) foil. It has been shown that PEN foils with thicknesses in the range from 25 to 150 ⁇ m are suitable for OLED sizes of at least 50 cm 2 .
  • PEN polyethylene naphthalate
  • the protection layers 25, 35 are provided with the driving electronics of the light unit 30.
  • ELaR Electronics on Plastic by Laser Release
  • the protection layers 25, 35 are arranged by spin-coating of material onto the light unit 30 (followed by curing of the protection layers). As is recognized by those skilled in the art, the protection layers 25, 35 can be arranged on the light unit 30 by any suitable method.
  • the advantages of providing a reelable OLED with a large-area support structure is that the device can be used in large-area applications, as will be described below.
  • the OLED 20 can be utilized as a large-area light source and can as such be given the form of a light-emitting curtain.
  • the radius of curvature for most applications as a reelable curtain renders possible a mechanical large-area support structure and protection by lamination with protection layers 25, 35.
  • the incorporation of the protection layers 25,35 involves adjustment of the flexibility of the device to match the desired radius of curvature.
  • a space partition device 50 comprising a reeling device 51 and an OLED 20.
  • the space partition device 50 further comprises a maneuvering device 53 which in this example is a thin chain; however, the space partition device 50 may alternatively be operated with a rod or with an electric motor, etc.
  • the OLED 20 engages with the reeling device 51 at a first end.
  • the OLED 20 is also arranged to be reelable onto said reeling device 51.
  • the space partition device 50 is used to partition off spaces in a room or the like. Three different states are achievable for the space partition device 50. First, as illustrated in Fig. 4 a), the OLED 20 may be fully reeled up onto the reeling device 51 , and no space partitioning is achieved.
  • the OLED 20 is reeled out and in its off-state, i.e. no electrical power is applied to the electrical contact 26 and the bottom electrode 22. No light is emitted from the OLED 20.
  • the OLED now partitions the space of the room. If the top electrode 23 is non-transparent, a non-transparent partition wall is created.
  • the top electrode 23 is at least semi-transparent and an at least semi-transparent partition wall is created.
  • the space partition device may be used as a transparent screen between two rooms in the off- state and as a visible screen in its on- state.
  • the OLED may also be reflecting, in which case it will act as a mirror.
  • the OLED 20 is reeled out and is set in its on-state, i.e. electrical power is applied to the contact 26 and the bottom electrode 22. Light is emitted from the OLED 20.
  • the partition wall thus created simultaneously provides a diffuse, large-area light sourcewhile at the same time partitioning off a space of the room. Thanks to the method of manufacturing the OLED 20 as one whole OLED, the fractional light-emitting area can be close to unity for the OLED 20.
  • the OLED 20 may also be partly rolled out while in the on-state and off-state such that the space is only partly partitioned by the space partition device 50 (not shown).
  • the space partition device 50 comprises a reeling device 51, an OLED 20, and an additional OLED 520 which is arranged with its first protection layer facing the first protection layer 25 of the OLED 20.
  • the space may be fully or partly divided thereby with non-transparent top electrodes, 23 (not shown), while respective large-area light sources are available in the two parts of the room.
  • the two OLEDs 20, 520 are preferably individually driven in the latter embodiment.
  • the driving electronics of the OLED 20 and the OLED 520 may be integrated in the protection layers 25, 35.
  • the driving of the OLEDs 20, 520 may be chosen in various ways, including a dimming possibility of the light.
  • the OLED 20 and the additional OLED 520 are arranged to emit light of respective predetermined colors.
  • the space partition device according to the previously described embodiments are advantageously used as a roller blind in a window.
  • the space partition device 50 may then be used to block out sunlight in the daytime and to prevent people from looking in through the window during both day and night.
  • the roller blind also provides a large-area light source which is advantageous for simulating daylight in a room.
  • a static pattern is applied in the light emission from the OLED 20.
  • the static pattern may be letters, figures and/or photographs.
  • the static pattern is applied in at least one layer of the OLED (24, 27, 22, 21, 23, 28, 25, 35).
  • the static pattern may be applied during OLED fabrication or afterwards.
  • At least one of the foils of the protection layers 25, 35 or the flexible bottom layer 24 contains a pattern, which may also be colored. A colored picture is thus obtained which may be illuminated by the OLED.
  • the device is provided with pixels and, if so desired, red, green and blue may be applied. Structuring of the anode and cathode in lines renders it possible tomanufacture a matrix, and the device can be used as a passive display, showing dynamic pictures.
  • the OLED 20 is arranged with pixels and each pixel contains control electronics and, if so desired, red, green and blue pixels can be made.
  • the control electronics may contain Thin Film Transistors (TFT), diodes, capacitors, or coils.
  • TFT Thin Film Transistors
  • the control electronics may be manufactured in an amorphous, micro or polycrystalline manufacturing process.
  • the OLED 20 according to the present invention is applied on a fixed wall as kind of a wallpaper, providing a diffuse, large-area light source in the on- state.
  • the organic electronic device 20 and/or the additional organic electronic device 520 is utilized in their photovoltaic mode. This is advantageous, for example, when utilizing the organic electronic device 520 as a solar cell in a roller blind in a window of a room, while the device 50 at the same time shields the room from sunlight. In the evening the organic electronic device 20 is utilized as a large-area light source. The sunlight shining on the solar cell 520 in the daytime may be used to charge a battery to use as a power source for the large-area light source, i.e. the organic electronic device 20, in the night time.
  • Embodiments of the OLED and method of manufacturing the OLED according to the present invention as defined in the appended claims have been described above.

Abstract

This invention relates to an organic light-emitting or light-absorbing device (20), comprising a light unit (30), a first flexible protection layer (35), and a second flexible protection layer (25). The light unit comprises a flexible bottom layer (24) having at least one first barrier layer (27). A bottom electrode (22) is provided on the flexible bottom layer, and an organic layer stack (21) is deposited on top of the bottom electrode. Furthermore, the organic layer stack is designed to emit or absorb light. The light unit has a top electrode (23) arranged on top of the organic layer stack and at least one second barrier (28) layer provided on top of the top electrode. The first flexible protection layer and the second flexible protection layer are arranged to encase the light unit, such that a large-area support structure is provided for the device. The large-area support structure provides a reelable organic light-emitting or light- absorbing device. The invention applies to flexibility and a method of adjusting this flexibility to the specific demands of specific large-area applications, such as space partition devices and roller blinds.

Description

Reelable OLED curtain
FIELD OF THE INVENTION
The present invention relates to organic light-emitting or light-absorbing devices, and more particularly to a reelable organic light-emitting or light-absorbing device for large-area applications and a method of manufacturing such a device.
BACKGROUND OF THE INVENTION
Organic light-emitting devices, OLEDs, for providing light sources and displays are known. A traditional OLED, as illustrated in Fig. 1, typically comprises a stack of organic layers 2 which are sandwiched between an anode 3 and a cathode 4. Typically an electrical contact 9 is electrically connected to the cathode 4. The stack of organic layers 2 comprises at least a light-emitting layer and is usually combined with one or more charge carrier and/or charge injection layers. In the original concept, indium tin oxide, ITO, is typically used as the anode 3 that is provided on a transparent substrate 5, e.g. a glass or a plastic plate. The anode 3 may be patterned in a desired way, e.g. as a pixel matrix. Typically, a metal having a low work function and covered with a protective metal like aluminum or a metal halide covered with aluminum is deposited on the stack of organic layers 2 to act as the cathode 4. When a voltage is applied across the stack of organic layers 2, light is produced in the light-emitting layer. The light can escape through the transparent anode 3 and the transparent substrate 5. These devices can be used both as displays and diffuse homogeneous light sources.
An OLED needs encapsulation by a cover 6 to prevent degradation through interaction with the ambient atmosphere. Water vapor is considered a harmful component for the OLED. Even when the OLED is provided with an encapsulating cover 6, a getter 7 is normally inserted in the cavity between the cover 6 and the substrate 5 to remove water penetrating through glue 8 that is used as an edge sealant for the cover 6.
Recently it has become of great interest to manufacture flexible OLEDs. The substantial difference between a traditional OLED, as described above, and a flexible OLED is that in the original concept both the substrate 5 and the encapsulating cover 6 are rigid, e.g. in the form of a glass substrate and a glass cover. Both the substrate and the cover are made in flexible materials in the case of flexible OLEDs. A plastic foil may be used as a substrate for the purpose of providing flexibility. When plastic foils are used as the substrate, these must be combined with a barrier layer to prevent water diffusion through the substrate. Such a barrier layer is also a prerequisite for encapsulation as an alternative to the glass cover of the traditional OLED. Sugimoto et. al, Selected Topics in Quantum Electronics, IEEE Journal of Volume 10, Issue 1, Jan.-Feb. 2004 Page(s): 107 - 114 Digital Object Identifier, 10.1109/JSTQE.2004.824112, provides a flexible OLED with plastic substrates. A barrier film on a plastic substrate and a passivation film on the OLED itself are presented.
An OLED is an organic electronic device. As described above, OLEDs typically comprise a plurality of organic layers arranged between two transparent electrodes, amongst which organic layers at least one layer is optoelectronically active, e.g. light- emitting as in the previous description. The light-emitting layer is an organic material that is capable of emitting light in response to receiving a voltage in a light-emitting mode. However, the optoelectronically active layer in an organic electronic device can also be used in a photovoltaic state, i.e. a photovoltaic layer. A photovoltaic layer generates a current and/or a voltage when receiving and absorbing light in a photovoltaic mode. Thus, applying a voltage across the electrodes in the light-emitting mode causes light to be emitted from the light-emitting organic layer, and shining light on the device in the photovoltaic mode results in a current and/or voltage generated at the electrodes. Well-known organic electronic devices that utilize the photovoltaic mode are solar cells.
Very thin flexible OLEDs open up the possibility for attractive foldable display devices, and the companies in the field of display technology are racing to provide the best foldable displays. Also very thin foldable organic light-absorbing devices, i.e. with the organic electronic device being used in the photovoltaic state, open up new applications. Not many prior art solutions focus on flexible large-area light-emitting or light-absorbing applications. These devices may be used, for example, to provide curved objects with a light- emitting surface or, if flexibility is sufficient, create reelable OLEDs for large-area lighting applications.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a reelable organic light- emitting or light-absorbing device, and a method of manufacturing such a reelable organic light-emitting or light-absorbing device suitable for flexible large-area light-emitting or light- absorbing applications. This object is achieved by an organic light-emitting or light-absorbing device and a method of manufacturing an organic light-emitting or light-absorbing device according to the present invention as defined in the independent claims 1 and 14.
Thus, in accordance with a first aspect of the present invention, there is provided an organic light-emitting or light-absorbing device comprising a light unit, which comprises a flexible bottom layer having at least one first barrier layer. A bottom electrode is provided on top of the at least one first barrier layer. Furthermore, an organic layer stack is deposited on top of the bottom electrode. The organic layer stack is designed to emit or absorb light. A top electrode is arranged on top of the organic layer stack, and at least one second barrier layer is provided on top of the top electrode. The device further comprises a first flexible protection layer and a second flexible protection layer. The first flexible protection layer and the second flexible protection layer are arranged to encase the light unit, such that a large area support structure is provided for the device and such that the device is reelable. Thus, there is provided a strong organic light-emitting or light-absorbing device suitable for large-area applications. Providing the flexible light unit, which by itself is extremely flexible, with protection layers renders it possible to arrange the device in an application that is exposed to mechanical stresses during use. The unique selling points of OLEDs for large-area lighting purposes are beyond dispute in the lighting community. Since the OLED intrinsically is a large-area device that provides diffuse, homogenous light which is pleasant to look at, i.e. which provides low contrast and saturated colors, these devices are very attractive for use in large-area applications. This is in sharp contrast to its counterpart, the inorganic LED, which is a high-brightness point source. With inorganic LEDs all kind of "tricks" have to be played in order to obtain large-area light sources. Other benefits of OLEDs are their free form factor, transparency, flexibility, ultrathin dimensions, and low- cost manufacture. The current invention relates to flexibility and a way to adjust this flexibility to the specific demands of the application.
In accordance with an embodiment of the device, the thickness of the first flexible protection layer and the second flexible protection layer is chosen in a range between 1 and 5000 micrometers.
In accordance with an embodiment of the device, the flexible bottom layer is a plastic foil.
In accordance with an embodiment of the device, the flexible bottom layer is a metal foil. In accordance with an embodiment of the device, the top electrode is at least semi-transparent, thus providing an at least semi transparent OLED.
In accordance with an embodiment of the device, a static pattern is applied in at least one layer of the device, such that an attractive pattern or static information is integrated in the large-area lighting application.
In accordance with an embodiment of the device, a dynamic pattern is applied in at least one layer, providing the ability to apply dynamic patterns and/or information in the large-area light-emitting or light-absorbing application.
In accordance with an embodiment of the device, the device is provided with pixels, and each pixel contains control electronics.
In accordance with an embodiment of the device, the device is utilized as wallpaper.
In accordance with an embodiment of the device, there is provided a spatial partition device comprising a reeling device and an organic light-emitting or light-absorbing device according to the present invention, which device is in engagement with the reeling device at a first end. Furthermore, the organic light-emitting or light-absorbing device is arranged such that it can be reeled onto the reeling device. Thus a space partition device is provided which can advantageously assume three different states. This will be described for the organic light-emitting or light-absorbing device when used in the light-emitting state: First, the OLED may be fully reeled up onto the reeling device, in which state no space partition is achieved. Second, when the OLED is reeled out and in its off-state, the OLED partitions the space of the room. Third, when the OLED is reeled out and in its on-state, the OLED partitions the room and at the same time acts as a large-area light source in one part of the partitioned space. In an embodiment, the space partition device further comprises an additional organic light-emitting or light-absorbing device according to the present invention. The bottom layer of the additional organic light emitting or light absorbing device is arranged facing the bottom substrate layer of the organic light emitting or light absorbing device. When having two OLEDs arranged in the space partition device, the space partition device can be arranged as a large area light source for both parts of the partitioned space. The individual OLEDs may be separately driven.
In an embodiment of the space partition device, the organic light-emitting or light-absorbing device and the additional organic light-emitting or light-absorbing device emit light of respective predetermined colors in the light-emitting state. In an embodiment, the space partition device is utilized as a roller blind. In accordance with a second aspect of the present invention, there is provided a method of manufacturing an OLED, comprising the steps of: providing a support substrate, - arranging a light unit by on the support substrate: providing a flexible bottom layer on the support substrate, applying at least one first barrier layer to the flexible bottom layer, providing a bottom electrode on the at least one first barrier layer, depositing an organic layer stack on top of the bottom electrode, - providing a top electrode on top of the organic layer stack, and providing at least one second barrier layer on top of the top electrode, providing a first flexible protection layer on the second barrier layer, removing the light unit from the support substrate, providing a second flexible protection layer on the flexible bottom layer. The first protection layer and the second protection layer provide a large-area support structure such that the device is reelable.
In accordance with an embodiment of the method, the thicknesses of the flexible protection layers are chosen in a range between 1 and 5000 micrometer.
These and other aspects, features, and advantages of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail and with reference to the appended drawings, in which: Fig. 1 is a cross-sectional view of a typical prior art organic light-emitting device,
Fig. 2 is a cross-sectional view of an embodiment of an organic light-emitting or light-absorbing device according to the present invention,
Figs. 3 a) to i) are illustrations presenting cross-sectional views of an organic light-emitting or light-absorbing device being manufactured in accordance with an embodiment of a method of manufacturing an organic light-emitting or light-absorbing device according to the present invention, and
Figs. 4 a) to d) illustrate space partition devices according to embodiments of the present invention. DESCRIPTION OF PREFERRED EMBODIMENTS
The present inventive concept is suitable for organic light-emitting or light- absorbing devices. An organic light-emitting device is described for the sake of simplicity in the following embodiments of a device according to the present invention, but the concept is also suitable for an inorganic light-absorbing device.
An organic light-emitting device, OLED, according to a first aspect of the present invention is described below with reference to Fig. 2. The OLED 20 comprises a light unit 30 (Figs. 3 h and i clarify the light unit 30). In Fig. 2, the light unit is arranged having a flexible bottom layer 24 on which at least one first barrier layer 27 is deposited. The first barrier layer 27 may comprise a number of thin- film barrier layers that are stacked so as to form a protection against moisture or gas. The flexible bottom layer 24 in this exemplifying embodiment is arranged as a polyimide film, i.e. a plastic foil. Any other suitable flexible polymeric material, such as e.g. polyethylene terephthalate (PET) and polypropylene, may alternatively serve as the flexible bottom layer for the device.
A conductive layer is provided on top of the first barrier layer 27 so as to form a bottom electrode 22, i.e. an anode. The bottom electrode 22 is transparent. A well-known method of providing a transparent, conducting anode layer is to deposit a thin layer of Indium Tin Oxide, ITO. Furthermore, an organic layer stack 21 is arranged on top of the transparent bottom electrode 22. The organic layer stack 21 is designed to emit light and comprises light- emitting layers and one or more charge carrier and/or charge injection layers, which are not explicitly shown in the figures. The organic layer stack 21 can be designed to emit light of a predetermined color. A top electrode 23 is arranged on the organic layer stack 21.
A second barrier layer 28 is arranged on the top electrode 23. The second barrier layer 28 may comprise a plurality of thin-film layers which are designed to keep water and atmospheric gases away from the sensitive top electrode and the organic layers of the organic layer stack 21. Furthermore, the light unit is arranged so as to have an electrical contact 26 for powering the light unit.
The OLED 20 is further arranged such that the light unit 30 is provided with a large-area support structure comprising a first flexible protection layer 35 and a second flexible protection layer 25. The second flexible protection layer 25 is arranged at the flexible bottom layer 24 and the first flexible protection layer 35 is arranged at the second barrier layer 28. The first flexible protection layer 35 and the second flexible protection layer 25 are arranged at the light unit 30 and act as a large-area protection structure for mechanical protection of the device.
The thickness of the first flexible protection layer 35 and the second flexible protection layer 25 is typically chosen in the range from 1 to 5000 μm. The thickness of these flexible protection layers 25 and 35 is preferably tuned to match the radius of curvature for a specific application. The large-area support structure which is formed by laminating of the light unit 30 with the protection layers 25, 35 is so flexible that the OLED 20 is reelable.
In alternative embodiments, the protection layers 25, 35 are arranged on the light unit 30 by spin-coating of the first protection layer 35 and the second protection layer 25 onto the light unit.
In an embodiment of an OLED according to the present invention, the top electrode 23 is at least semi-transparent. This way the light emitted from the organic layer stack 21 can exit the OLED 20 through the lower side, i.e. passing through the transparent bottom electrode 22 and the at least semi-transparent top electrode 23. At least semi- transparent electrodes can be achieved by various techniques, see e.g. US Patent 6885149 or US Patent 5739545.
According to a second aspect of the present invention, there is provided a method of manufacturing an OLED which will now be described with reference to Figs. 3 a) to i). In order to facilitate the handling of a flexible bottom layer 24, for example a plastic foil as described above, it is practical first to provide a rigid carrier, i.e. a support substrate 40, during the processing of the OLED, cf. Fig. 3 a). The support substrate 40, e.g. a standard glass plate, is temporarily used during the manufacturing of the light unit 30 of the OLED 20.
Utilizing the support structure 40, the manufacture of the light unit 30 is started by providing a flexible bottom layer 24. This may be done by coating the support substrate 40 with a thin layer of polyimide in a standard spin-coating procedure used in display technology. The polyimide is cured so as to form the flexible bottom layer 24, cf. Fig. 3 b).
To protect the OLED from moisture and further processing steps, at least one thin- film first barrier layer 27 is now applied on top of the flexible bottom layer 24. The first barrier layer 27 is provided on the flexible bottom layer 24 to act as a thin-film water barrier. However, the first barrier layer 27 also helps protect the polyimide film 24 during the remaining processing of the OLED, e.g. during the deposition of the bottom electrode 22 and the organic layer stack 21. A bottom electrode 22 is now arranged on top of the first barrier layer 27 through deposition of a thin ITO-layer by means of e.g. sputtering, or some nano composite printing technique, cf. Fig. 3 d). Other common transparent conductive oxides for transparent electrodes include e.g. ZnO:Al and SnO2IF. The organic layer stack 21 is now processed on top of the bottom elctrode 22, cf. Fig. 3 e). This is followed by providing a top electrode 23 and appopriate contact means 26, cf. Fig. 3 f).
Subsequently, at least one second barrier layer 28 is arranged on top of the top electrode 23 to seal the light unit 30, cf. Fig. 3 g). Next, the light unit 30 and the support substrate 40 are separated, cf. Fig. 3 h).
A laser release process is used to remove the glass substrate 40. The support substrate 40 may be reused for the manufacture of more light units 30. The resulting light unit 30 can be as thin as 10 μm and shows extreme flexibility, the radius of curvature being well below 1 cm. Such ultrathin light units with thicknesses down to 10 μm (which are flexible like e.g. cigarette paper), however, are not practicable for large area applications. For these applications the light unit 30 is placed between a first flexible protection layer 35 and a second flexible protection layer 25. These protection layers may be applied by lamination of foils, by spin coating of a layer, or by other deposition techniques. The protection layers provide a large- area support structure for the mechanical protection for the OLED 20. The thicknesses of the protection layers 25, 35 are typically chosen in a range from 1 to 5000 μm, and the flexibility of the OLED 20 can be tuned to match the radius of curvature for a specific application through adaptiation of the thickness of the protection layers 25, 35 to a suitable value.
In an embodiment, the first flexible protection layer 35 and the second flexible protection layer 25 are arranged by a standard lamination technique using polyethylene naphthalate (PEN) foil. It has been shown that PEN foils with thicknesses in the range from 25 to 150 μm are suitable for OLED sizes of at least 50 cm2.
In an alternative embodiment of the method, the protection layers 25, 35 are provided with the driving electronics of the light unit 30.
In the embodiment of the method of manufacturing an OLED as described above, a process called Electronics on Plastic by Laser Release (EPLaR) is utilized. This technology, developed by Philips Research, may be studied in detail in WO2005050754 and is incorporated herein by reference. When the EpLaR process is used, the intrinsic flexibility of the produced light unit 30 is so extremely high, that the second protection layer 25 is applied to the light unit 30 before the support substrate 40 is detached therefrom. An alternative embodiment of the method comprises roll-to-roll (R2R) processes in transparent thin plastic foils.
In yet another alternative embodiment, the protection layers 25, 35 are arranged by spin-coating of material onto the light unit 30 (followed by curing of the protection layers). As is recognized by those skilled in the art, the protection layers 25, 35 can be arranged on the light unit 30 by any suitable method.
The advantages of providing a reelable OLED with a large-area support structure is that the device can be used in large-area applications, as will be described below. The OLED 20 can be utilized as a large-area light source and can as such be given the form of a light-emitting curtain. The radius of curvature for most applications as a reelable curtain renders possible a mechanical large-area support structure and protection by lamination with protection layers 25, 35. The incorporation of the protection layers 25,35 involves adjustment of the flexibility of the device to match the desired radius of curvature.
In an embodiment of the present invention as illustrated in Fig. 4, a space partition device 50 is provided comprising a reeling device 51 and an OLED 20. The space partition device 50 further comprises a maneuvering device 53 which in this example is a thin chain; however, the space partition device 50 may alternatively be operated with a rod or with an electric motor, etc. The OLED 20 engages with the reeling device 51 at a first end. The OLED 20 is also arranged to be reelable onto said reeling device 51. The space partition device 50 is used to partition off spaces in a room or the like. Three different states are achievable for the space partition device 50. First, as illustrated in Fig. 4 a), the OLED 20 may be fully reeled up onto the reeling device 51 , and no space partitioning is achieved. In Fig. 4 b), the OLED 20 is reeled out and in its off-state, i.e. no electrical power is applied to the electrical contact 26 and the bottom electrode 22. No light is emitted from the OLED 20. The OLED now partitions the space of the room. If the top electrode 23 is non-transparent, a non-transparent partition wall is created.
In an alternative embodiment, the top electrode 23 is at least semi-transparent and an at least semi-transparent partition wall is created. Given such a transparent top electrode, the space partition device may be used as a transparent screen between two rooms in the off- state and as a visible screen in its on- state. The OLED may also be reflecting, in which case it will act as a mirror.
In Fig. 4 c) the OLED 20 is reeled out and is set in its on-state, i.e. electrical power is applied to the contact 26 and the bottom electrode 22. Light is emitted from the OLED 20. The partition wall thus created simultaneously provides a diffuse, large-area light sourcewhile at the same time partitioning off a space of the room. Thanks to the method of manufacturing the OLED 20 as one whole OLED, the fractional light-emitting area can be close to unity for the OLED 20.
The OLED 20 may also be partly rolled out while in the on-state and off-state such that the space is only partly partitioned by the space partition device 50 (not shown).
In an alternative embodiment, the space partition device 50 comprises a reeling device 51, an OLED 20, and an additional OLED 520 which is arranged with its first protection layer facing the first protection layer 25 of the OLED 20. The space may be fully or partly divided thereby with non-transparent top electrodes, 23 (not shown), while respective large-area light sources are available in the two parts of the room. The two OLEDs 20, 520 are preferably individually driven in the latter embodiment. As was described above, the driving electronics of the OLED 20 and the OLED 520 may be integrated in the protection layers 25, 35. The driving of the OLEDs 20, 520 may be chosen in various ways, including a dimming possibility of the light. In an alternative embodiment, the OLED 20 and the additional OLED 520 are arranged to emit light of respective predetermined colors.
The space partition device according to the previously described embodiments are advantageously used as a roller blind in a window. The space partition device 50 may then be used to block out sunlight in the daytime and to prevent people from looking in through the window during both day and night. In the on-state, the roller blind also provides a large-area light source which is advantageous for simulating daylight in a room.
In an embodiment of the OLED 20, a static pattern is applied in the light emission from the OLED 20. The static pattern may be letters, figures and/or photographs. The static pattern is applied in at least one layer of the OLED (24, 27, 22, 21, 23, 28, 25, 35). The static pattern may be applied during OLED fabrication or afterwards.
In another embodiment, at least one of the foils of the protection layers 25, 35 or the flexible bottom layer 24 contains a pattern, which may also be colored. A colored picture is thus obtained which may be illuminated by the OLED.
In another embodiment of the OLED 20, the device is provided with pixels and, if so desired, red, green and blue may be applied. Structuring of the anode and cathode in lines renders it possible tomanufacture a matrix, and the device can be used as a passive display, showing dynamic pictures.
In yet another embodiment, the OLED 20 is arranged with pixels and each pixel contains control electronics and, if so desired, red, green and blue pixels can be made. The control electronics may contain Thin Film Transistors (TFT), diodes, capacitors, or coils. The control electronics may be manufactured in an amorphous, micro or polycrystalline manufacturing process.
In another embodiment, the OLED 20 according to the present invention is applied on a fixed wall as kind of a wallpaper, providing a diffuse, large-area light source in the on- state.
In alternative embodiments, the organic electronic device 20 and/or the additional organic electronic device 520 is utilized in their photovoltaic mode. This is advantageous, for example, when utilizing the organic electronic device 520 as a solar cell in a roller blind in a window of a room, while the device 50 at the same time shields the room from sunlight. In the evening the organic electronic device 20 is utilized as a large-area light source. The sunlight shining on the solar cell 520 in the daytime may be used to charge a battery to use as a power source for the large-area light source, i.e. the organic electronic device 20, in the night time. Embodiments of the OLED and method of manufacturing the OLED according to the present invention as defined in the appended claims have been described above. These should be seen as merely non-limiting examples. As understood by those skilled in the art, many modifications and alternative embodiments are possible within the scope of the invention. It is to be noted that for the purposes of this application, and in particular with regard to the appended claims, the word "comprising" does not exclude other elements or steps, that the word "a" or "an", does not exclude a plurality, which per se will be apparent to those skilled in the art.

Claims

CLAIMS:
1. An organic light-emitting or light-absorbing device (20), comprising a light unit (30) comprising: a flexible bottom layer (24) comprising at least one first barrier layer (27), on which at least one first barrier layer a bottom electrode (22) is provided; - an organic layer stack (21) deposited on top of said bottom electrode and designed to emit or absorb light; a top electrode (23) arranged on top of the organic layer stack; at least one second barrier (28) layer provided on top of said top electrode; and a first flexible protection layer (35) and a second flexible protection layer (25); wherein said first flexible protection layer and said second flexible protection layer are arranged to encase said light unit whereby a large-area support structure is provided for the device such that said device is reelable.
2. An organic light-emitting or light-absorbing device according to claim 1, wherein the thickness of said first flexible protection layer (35) and said second flexible protection layer (25) is chosen to lie within a range of between 1 and 5000 micrometers.
3. An organic light-emitting or light-absorbing device according to claim 1 or 2, wherein said flexible bottom layer (24) is a plastic foil.
4. An organic light-emitting of light-absorbing device according to claim 1 or 2, wherein said flexible bottom layer (24) is a metal foil
5. An organic light-emitting or light-absorbing device according to any one of claims 1 to 3, wherein said top electrode (23) is at least semi-transparent.
6. An organic light-emitting or light-absorbing device according to any one of the preceding claims, wherein a static pattern is applied in at least one layer (24, 27, 22, 21, 23, 28, 25, 35).
7. An organic light-emitting or light-absorbing device according to any one of the preceding claims, wherein a dynamic pattern is applied in at least one layer (24, 27, 22, 21, 23, 28, 25, 35).
8. An organic light-emitting or light-absorbing device according to any one of the preceding claims, wherein said device is provided with pixels, and each pixel contains control electronics.
9. An organic light-emitting or light-absorbing device according to any one of the preceding claims, utilized as wallpaper.
10. A space partition device (50) comprising a reeling device (51); and an organic light-emitting or light-absorbing device (20) according to any one of claims 1 to 8 in engagement with said reeling device at a first end, and further being - arranged to be reelable onto said reeling device.
11. A space partition device (55) according to claim 10, further comprising an additional organic light-emitting or light-absorbing device (520) according to any one of claims 1 to 8, wherein the bottom layer of said additional organic light-emitting or light- absorbing device is arranged so as to face the bottom layer (24) of said organic light-emitting or light-absorbing device (20).
12. A space partition device according to claim 11, wherein said organic light- emitting or light-absorbing device (20) and said additional organic light-emitting or light- absorbing device (520) emit light of respective predetermined colors.
13. A space partition device according to any one of claims 10 to 12, being utilized as a roller blind.
14. A method of manufacturing an organic light-emitting or light-absorbing device comprising the steps of: providing a support substrate (40); arranging a light unit (30) on said support substrate by: - providing a flexible bottom layer (24) on said support substrate; applying at least one first barrier layer (27) to said flexible bottom layer; providing a bottom electrode (22) on said at least one first barrier layer; - depositing an organic layer stack (21) on top of said bottom electrode; providing a top electrode (23) on top of the organic layer stack; and providing at least one second barrier layer (28) on top of said top electrode; providing a first flexible protection layer (35) on said second barrier layer; - removing said light unit from said support substrate; and providing a second flexible protection layer (25) on said flexible bottom layer; wherein said first protection layer and said second protection layer provide a large-area support structure such that said device is reelable.
15. A method according to claim 14, wherein the thicknesses of the first flexible protection layer (35) and the second flexible protection layer (25) are chosen to lie within a range between 1 and 5000 micrometer.
PCT/IB2009/051687 2008-05-06 2009-04-24 Reelable oled curtain WO2009136305A1 (en)

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