Flexible organic electronic device with improved resistance to oxygen and moisture degradation

Abstract

Flexible composite barrier structures are used to improve the resistance, to oxygen and moisture degradation, of an organic electronic device including at least one active layer comprising an organic material.

What is claimed is:  
     
         1 . A flexible organic electronic device comprising in the order listed: 
 a) a first flexible composite barrier structure comprising at least one layer of a first polymeric film and at least one layer of a first barrier material, the first barrier structure having a first inner surface;    b) at least one first electrical contact layer;    c) at least one active layer comprising an organic active material, said active layer having dimensions defined by a length and a width;    d) at least one second electrical contact layer;    e) a second flexible composite barrier structure comprising at least one layer of a second polymeric film and at least one layer of a second barrier material, the second barrier structure having a second inner surface;    wherein at least one of the first and second composite barrier structures is light-transmitting;    wherein the first and second composite barrier structures are sealed together to envelop the at least one active layer.    
     
     
         2 . The device of  claim 1  wherein a portion of the first electrical contact layer and a portion of the second electrical contact layer extend beyond the dimensions of the active layer, wherein the first and second composite barrier structures are also sealed to the extended portions of the first and second electrical contact layers.  
     
     
         3 . The device of  claim 1  wherein the one second electrical contact layer comprises a material having a lower work function than the first electrical contact layer.  
     
     
         4 . The device of  claim 1  wherein the first electrical contact layer is an anode and the second electrical contact layer is a cathode.  
     
     
         5 . The device of  claim 1  wherein the first and second polymeric films of the first and second composite barrier structures are selected from polyolefins, polyesters, polyimides, polyamides, polyacrylonitrile and polymethacrylonitrile; perfluorinated and partially fluorinated polymers, polycarbonates, polyvinyl chloride, polurethanes, polyacrylic resins, epoxy resins, and novolac resins.  
     
     
         6 . The device of  claim 1  wherein the first and second barrier materials are independently selected from metals, metal alloys, inorganic oxides, inorganic nitrides, inorganic carbides, inorganic fluorides, and combinations thereof.  
     
     
         7 . The device of  claim 1  wherein the first flexible composite barrier structure and the first electrical contact layer are light-transmitting.  
     
     
         8 . The device of  claim 7  wherein the first and second polymeric films in the first composite barrier material are selected from polyethylene terephthalate, polyethylene naphthalate, polyimide, and combinations thereof.  
     
     
         9 . The device of  claim 1  wherein the barrier material is selected from aluminum, nickel, chromium, copper, tin, stainless steel, and alloys thereof.  
     
     
         10 . The device of  claim 1  wherein the a barrier material selected from inorganic oxides, inorganic nitrides, inorganic fluorides, inorganic carbides, and combinations thereof.  
     
     
         11 . The device of  claim 1  wherein the layer of first and second barrier materials has a thickness in the range of 2-500 nm.  
     
     
         12 . The device of  claim 1  wherein the first flexible composite barrier structure comprises two layers of polymeric film with a layer of the first barrier material therebetween.  
     
     
         13 . The device of  claim 1  wherein the second flexible composite barrier structure comprises two layers of polymeric film with a layer of the second barrier material there between.  
     
     
         14 . The device of  claim 1  wherein the first flexible composite barrier structure further comprises a layer of adhesive on the first inner surface.  
     
     
         15 . The device of  claim 1  wherein the second flexible composite barrier structure further comprises a layer of adhesive on the second inner surface.  
     
     
         16 . The device of  claim 1  wherein at least one of the first inner surface and the second inner surface contains an adhesive component.  
     
     
         17 . The device of  claim 14  or  claim 15  wherein the adhesive is selected from polymer adhesive resins, amorphous polyesters, copolyesters, polyester blends, nylon, polyurethanes, polyolefins, vinyl alcohol, ethylene vinylacetate copolymer, copolymers of ionomers and acids, and combinations thereof.  
     
     
         18 . The device of  claim 16  wherein the adhesive component is selected from polymer adhesive resins, amorphous polyesters, copolyesters, polyester blends, nylon, polyurethanes, polyolefins, vinyl alcohol, ethylene vinylacetate copolymer, copolymers of ionomers and acids, and combinations thereof.  
     
     
         19 . The device of  claim 1 , wherein the active layer includes electroluminescent material.  
     
     
         20 . The device of  claim 1 , wherein the active layer includes a conjugated polymer.  
     
     
         21 . An electroluminescent display containing the device of  claim 1 .  
     
     
         22 . A photodetector containing the device of  claim 1 .  
     
     
         23 . A method for improving resistance to oxygen and moisture degradation of a flexible organic electronic device comprising at least one first electrical contact layer having a first electrical contact layer outer surface and an opposite first electrical contact layer inner surface, at least one active layer adjacent to the first electrical contact layer inner surface, the active layer comprising an organic active material, said active layer having a set of dimensions, and at least one second electrical contact layer having a second electrical contact layer outer surface and an opposite second electrical contact layer inner surface, wherein the second electrical contact layer inner surface is adjacent to the active layer, the method comprising the steps of: 
 placing a first flexible composite barrier structure adjacent to the at least one first electrical contact layer outer surface, the first flexible composite barrier structure comprising at least one layer of a first polymeric film and at least one layer of a first barrier material, the first barrier structure having a first inner surface;    placing a second flexible composite barrier structure adjacent to the at least one second electrical contact layer outer surface, the second flexible composite barrier structure comprising at least one layer of a second polymeric film and at least one layer of a second barrier material, the second barrier structure having a second inner surface;    wherein at least one of the first and second composite barrier structures is light-transmitting,    sealing the first inner surface and the second inner surface together outside the dimensions of the active layer to envelop the active layer.    
     
     
         24 . The method of  claim 23  wherein a portion of the first electrical contact layer and a portion of the second electrical contact layer extend beyond the dimensions of the active layer, wherein the first and second composite barrier structures are also sealed to the extended portions of the first and second electrical contact layers.  
     
     
         25 . The method of  claim 23  wherein the second electrical contact layer comprises a material having a lower work function than the first electrical contact layer.  
     
     
         26 . The method of  claim 23  wherein the first electrical contact layer is a cathode and the second electrical contact layer is an anode.  
     
     
         27 . The method of  claim 23  wherein the first and second polymeric films of the first and second composite barrier structures are selected from polyolefins, polyesters, polyimides, polyamides, polyacrylonitrile and polymethacrylonitrile; perfluorinated and partially fluorinated polymers, polycarbonates, polyvinyl chloride, polurethanes, polyacrylic resins, epoxy resins, and novolac resins.  
     
     
         28 . The method of  claim 23  wherein the first and second barrier materials are selected from metals, metal alloys, inorganic oxides, inorganic nitrides, inorganic carbides, inorganic fluorides, and combinations thereof.  
     
     
         29 . The method of  claim 23  wherein the first flexible composite barrier structure and the first electrical contact layer are light-transmitting.  
     
     
         30 . The method of  claim 23  wherein the first and second polymeric films in the first composite barrier material is selected from polyethylene terephthalate, polyethylene naphthalate, polyimide, and combinations thereof.  
     
     
         31 . The method of  claim 23  wherein the barrier material is selected from aluminum, nickel, chromium, copper, tin, stainless steel, and alloys thereof.  
     
     
         32 . The method of  claim 23  wherein the barrier material selected from inorganic oxides, inorganic nitrides, inorganic fluorides, inorganic carbides, and combinations thereof.  
     
     
         33 . The method of  claim 23  wherein the layer of first and second barrier materials has a thickness in the range of 2-500 nm.  
     
     
         34 . The method of  claim 23  wherein the first flexible composite barrier structure comprises two layers of polymeric film with a layer of the first barrier material therebetween.  
     
     
         35 . The method of  claim 23  wherein the second flexible composite barrier structure comprises two layer of polymeric film with a layer of the first barrier material therebetween.  
     
     
         36 . The method of  claim 23  wherein the first flexible composite barrier structure further comprises a layer of adhesive on the first inner surface.  
     
     
         37 . The method of  claim 23  wherein the second flexible composite barrier structure further comprises a layer of adhesive on the second inner surface.  
     
     
         38 . The method of  claim 23  wherein at least one of the first inner surface and the second inner surface contains an adhesive component.  
     
     
         39 . The method of  claim 36  or  37  wherein the adhesive is selected from polymer adhesive resins, amorphous polyesters, copolyesters, polyester blends, nylon, polyurethanes, polyolefins, vinyl alcohol, ethylene vinylacetate copolymer, copolymers of ionomers and acids, and combinations thereof.  
     
     
         40 . The method of  claim 38  wherein the adhesive component is selected from polymer adhesive resins, amorphous polyesters, copolyesters, polyester blends, nylon, polyurethanes, polyolefins, vinyl alcohol, ethylene vinylacetate copolymer, copolymers of ionomers and acids, and combinations thereof.  
     
     
         41 . The method of  claim 23 , wherein the active layer includes electroluminescent material.  
     
     
         42 . The method of  claim 23 , wherein the active layer includes a conjugated polymer.