Multilayered electrode/substrate structures and display devices incorporating the same

Abstract

Multilayered electrode/substrate structures and display devices incorporating the same include a plastic substrate and at least one conductive layer overlying the plastic substrate. The at least one conductive layer is laser-etched into discrete conductive elements. In a preferred embodiment, the multilayered electrode/substrate structure includes a flexible “glass replacement” structure or composite which incorporates one or more functional layers therein. One or more functional layers of the multilayered electrode/substrate structure serve to insulate, promote adhesion, protect layers underneath from laser irradiation, provide protection from environmental damage, and/or provide protection from structural damage.

We claim:  
     
         1 . A multilayered electrode/substrate structure comprising: 
 a plastic substrate; and    at least one conductive layer overlying the plastic substrate, the at least one conductive layer being excimer laser-etched into a plurality of discrete conductive elements.    
     
     
         2 . The multilayered electrode/substrate structure of  claim 1  wherein the plastic substrate comprises polyethylene terephthalate (PET), polyethylenenapthalate (PEN), polyethersulphone (PES), polycarbonate (PC) or a cyclic polyolefin.  
     
     
         3 . The multilayered electrode/substrate structure of  claim 1  wherein the plastic substrate comprises a polyolefin material or a cyclic polyolefin.  
     
     
         4 . The multilayered electrode/substrate structure of  claim 1  wherein the at least one conductive layer comprises an oxide layer.  
     
     
         5 . The multilayered electrode/substrate structure of  claim 1  wherein the at least one conductive layer comprises an indium tin oxide (ITO) layer.  
     
     
         6 . The multilayered electrode/substrate structure of  claim 5  wherein the ITO layer is polycrystalline.  
     
     
         7 . The multilayered electrode/substrate structure of  claim 1  wherein the at least one conductive layer comprises an alloy.  
     
     
         8 . The multilayered electrode/substrate structure of  claim 7  wherein the alloy is an indium tin oxide (ITO) alloy.  
     
     
         9 . The multilayered electrode/substrate structure of  claim 1  wherein the at least one conductive layer comprises a metal-based layer.  
     
     
         10 . The multilayered electrode/substrate structure of  claim 1  wherein the at least one conductive layer comprises a silver-based layer.  
     
     
         11 . The multilayered electrode/substrate structure of  claim 1  wherein the at least one conductive layer comprises silver and gold.  
     
     
         12 . The multilayered electrode/substrate structure of  claim 1  wherein the at least one conductive layer is a multilayered conductive film.  
     
     
         13 . The multilayered electrode/substrate structure of  claim 1  wherein the at least one conductive layer, where it has not been etched, has a thickness between around 10 nm and around 120 mn.  
     
     
         14 . The multilayered electrode/substrate structure of  claim 1  wherein the at least one conductive layer has a resistivity of no greater than 80 Ω/square.  
     
     
         15 . The multilayered electrode/substrate structure of  claim 1  wherein the at least one conductive layer has a transmissivity of at least 80%.  
     
     
         16 . The multilayered electrode/substrate structure of  claim 1  wherein the at least one conductive layer is etched in a pattern with a line gap at least as small as 10 μm.  
     
     
         17 . The multilayered electrode/substrate structure of  claim 1 , further comprising: 
 at least one functional layer intermediate the plastic substrate and the at least one conductive layer, the at least one functional layer serving to electrically insulate the discrete conductive elements.    
     
     
         18 . The multilayered electrode/substrate structure of  claim 1 , further comprising: 
 at least one functional layer intermediate the plastic substrate and the at least one conductive layer, the at least one functional layer serving to promote adhesion of the at least one conductive layer to the plastic substrate.    
     
     
         19 . The multilayered electrode/substrate structure of  claim 1 , further comprising: 
 at least one functional layer intermediate the plastic substrate and the at least one conductive layer, the at least one functional layer serving to protect the plastic substrate from laser irradiation.    
     
     
         20 . The multilayered electrode/substrate structure of  claim 1 , further comprising: 
 at least one functional layer intermediate the plastic substrate and the at least one conductive layer, the at least one functional layer serving to protect one or more other functional layers including a barrier layer from laser irradiation.    
     
     
         21 . The multilayered electrode/substrate structure of  claim 1 , further comprising: 
 at least one functional layer intermediate the plastic substrate and the at least one conductive layer, the at least one functional layer serving to protect the plastic substrate from environmental damage caused by exposure to ambient air.    
     
     
         22 . The multilayered electrode/substrate structure of  claim 1 , further comprising: 
 at least one functional layer intermediate the plastic substrate and the at least one conductive layer, the at least one functional layer serving to protect the plastic substrate from environmental damage caused by exposure to moisture.    
     
     
         23 . The multilayered electrode/substrate structure of  claim 1 , further comprising: 
 an additional functional layer abutting a side of the plastic substrate that faces away from at least one conductive layer, the additional functional layer serving to provide structural protection and/or environmental protection for the plastic substrate.    
     
     
         24 . A multilayered electrode/substrate structure comprising: 
 a plastic substrate;    at least one conductive layer overlying the plastic substrate; and    at least one functional layer intermediate the plastic substrate and the at least one conductive layer, the at least one functional layer comprising an insulating material;    wherein portions of the at least one conductive layer are excimer laser etched.    
     
     
         25 . The multilayered electrode/substrate structure of  claim 24  wherein the plastic substrate comprises polyethylene terephthalate (PET), polyethylenenapthalate (PEN), polyethersulphone (PES), polycarbonate (PC) or a cyclic polyolefin.  
     
     
         26 . The multilayered electrode/substrate structure of  claim 24  wherein the plastic substrate comprises a polyolefin material or a cyclic polyolefin.  
     
     
         27 . The multilayered electrode/substrate structure of  claim 24  wherein the at least one conductive layer comprises an oxide layer.  
     
     
         28 . The multilayered electrode/substrate structure of  claim 24  wherein the at least one conductive layer comprises an indium tin oxide (ITO) layer.  
     
     
         29 . The multilayered electrode/substrate structure of  claim 28  wherein the ITO layer is polycrystalline.  
     
     
         30 . The multilayered electrode/substrate structure of  claim 24  wherein the at least one conductive layer comprises an alloy.  
     
     
         31 . The multilayered electrode/substrate structure of  claim 30  wherein the alloy is an indium tin oxide (ITO) alloy.  
     
     
         32 . The multilayered electrode/substrate structure of  claim 24  wherein the at least one conductive layer comprises a metal-based layer.  
     
     
         33 . The multilayered electrode/substrate structure of  claim 24  wherein the at least one conductive layer comprises a silver-based layer.  
     
     
         34 . The multilayered electrode/substrate structure of  claim 24  wherein the at least one conductive layer comprises silver and gold.  
     
     
         35 . The multilayered electrode/substrate structure of  claim 24  wherein the at least one conductive layer is a multilayered conductive film.  
     
     
         36 . The multilayered electrode/substrate structure of  claim 24  wherein the at least one conductive layer, where it has not been etched, has a thickness between around 10 nm and around 120 nm.  
     
     
         37 . The multilayered electrode/substrate structure of  claim 24  wherein the at least one conductive layer has a resistivity of no greater than 80 Ω/square.  
     
     
         38 . The multilayered electrode/substrate structure of  claim 24  wherein the at least one conductive layer has a transmissivity of at least 80%.  
     
     
         39 . The multilayered electrode/substrate structure of  claim 24  wherein the at least one conductive layer is etched in a pattern with a line gap at least as small as 10 μm.  
     
     
         40 . The multilayered electrode/substrate structure of  claim 24  wherein the at least one functional layer comprises a protective layer which serves to protect layers beneath the protective layer from laser irradiation.  
     
     
         41 . The multilayered electrode/substrate structure of  claim 40  wherein portions of the protective layer underlying the etched portions of the at least one conductive layer are not completely decomposed.  
     
     
         42 . The multilayered electrode/substrate structure of  claim 24  wherein the at least one functional layer comprises a layer of acrylic which abuts the at least one conductive layer.  
     
     
         43 . The multilayered electrode/substrate structure of  claim 24  wherein the at least one functional layer comprises a barrier layer which serves to protect the plastic substrate from environmental damage.  
     
     
         44 . The multilayered electrode/substrate structure of  claim 43  wherein the barrier layer is inorganic.  
     
     
         45 . The multilayered electrode/substrate structure of  claim 47  wherein the barrier layer has an oxygen transmission rate (OTR) no greater than 0.1 cc/m 2 /day.  
     
     
         46 . The multilayered electrode/substrate structure of  claim 47  wherein the barrier layer has a water vapor transmission rate (WVTR) no greater than 0.1 g/m 2 /day.  
     
     
         47 . The multilayered electrode/substrate structure of  claim 43  wherein the barrier layer comprises a layer of SiOx which abuts the plastic substrate.  
     
     
         48 . The multilayered electrode/substrate structure of  claim 24 , further comprising: 
 an additional functional layer abutting a side of the plastic substrate that faces away from the at least one conductive layer, the additional functional layer serving to provide structural protection and/or environmental protection for the plastic substrate.    
     
     
         49 . A multilayered electrode/substrate structure comprising: 
 a substrate;    a layer of indium tin oxide (ITO) which is polycrystalline; and    at least one functional layer, at least one of which serves as an adhesion promoter of the ITO layer to the substrate;    wherein portions of the ITO layer are excimer laser etched.    
     
     
         50 . The multilayered electrode/substrate structure of  claim 49  wherein the ITO layer, where it has not been etched, has a thickness between around 10 nm and around 120 nm.  
     
     
         51 . The multilayered electrode/substrate structure of  claim 49  wherein the ITO layer has a resistivity of no greater than 80 Ω/square.  
     
     
         52 . The multilayered electrode/substrate structure of  claim 49  wherein the ITO layer has a transmissivity of at least 80%.  
     
     
         53 . The multilayered electrode/substrate structure of  claim 49  wherein the ITO layer is etched in a pattern with a line gap at least as small as 10 μm.  
     
     
         54 . The multilayered electrode/substrate structure of  claim 49  wherein the substrate comprises plastic.  
     
     
         55 . The multilayered electrode/substrate structure of  claim 49  wherein the substrate comprises polyethylene terephthalate (PET), polyethylenenapthalate (PEN), polyethersulphone (PES) or polycarbonate (PC).  
     
     
         56 . The multilayered electrode/substrate structure of  claim 49  wherein the substrate comprises a polyolefin material.  
     
     
         57 . The multilayered electrode/substrate structure of  claim 49  wherein the at least one functional layer comprises a protective layer which serves to protect layers beneath the protective layer from laser irradiation.  
     
     
         58 . The multilayered electrode/substrate structure of  claim 57  wherein portions of the protective layer underlying the etched portions of the at least one conductive layer are not completely decomposed.  
     
     
         59 . The multilayered electrode/substrate structure of  claim 49  wherein the at least one functional layer comprises a layer of acrylic which abuts the ITO layer.  
     
     
         60 . The multilayered electrode/substrate structure of  claim 49  wherein the at least one functional layer comprises a barrier layer which serves to protect the substrate from environmental damage.  
     
     
         61 . The multilayered electrode/substrate structure of  claim 60  wherein the barrier layer is inorganic.  
     
     
         62 . The multilayered electrode/substrate structure of  claim 60  wherein the barrier layer has an oxygen transmission rate (OTR) no greater than 0.1 cc/m 2 /day.  
     
     
         63 . The multilayered electrode/substrate structure of  claim 60  wherein the barrier layer has a water vapor transmission rate (WVTR) no greater than 0.1 g/m 2 /day.  
     
     
         64 . The multilayered electrode/substrate structure of  claim 60  wherein the barrier layer comprises a layer of SiOx which abuts the substrate.  
     
     
         65 . The multilayered electrode/substrate structure of  claim 49 , further comprising: 
 an additional functional layer abutting a side of the substrate that faces away from the ITO layer, the additional functional layer serving to provide structural protection and/or environmental protection for the substrate.    
     
     
         66 . A liquid crystal display device incorporating the multilayered electrode/substrate structure of any of claims  1 - 65 .  
     
     
         67 . An organic light emitting device incorporating the multilayered electrode/substrate structure of any of claims  1 - 65 .