Method for edge sealing barrier films

Abstract

An edge-sealed barrier film composite. The composite includes a substrate and at least one initial barrier stack adjacent to the substrate. The at least one initial barrier stack includes at least one decoupling layer and at least one barrier layer. One of the barrier layers has an area greater than the area of one of the decoupling layers. The decoupling layer is sealed by the first barrier layer within the area of barrier material. An edge-sealed, encapsulated environmentally sensitive device is provided. A method of making the edge-sealed barrier film composite is also provided.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a division of U.S. patent application Ser. No. 09 / 966,163, filed Sep. 28, 2001, and entitled “METHOD FOR EDGE SEALING BARRIER FILMS” which is a continuation-in-part of U.S. patent application Ser. No. 09 / 427,138, filed Oct. 25, 1999, entitled “ENVIRONMENTAL BARRIER MATERIAL FOR ORGANIC LIGHT EMITTING DEVICE AND METHOD OF MAKING,” now U.S. Pat. No. 6,522,067, issued Feb. 18, 2003.BACKGROUND OF THE INVENTION [0002] The invention relates generally to multilayer, thin film barrier composites, and more particularly, to multilayer, thin film barrier composites having the edges sealed against lateral moisture and gas diffusion. [0003] Multilayer, thin film barrier composites having alternating layers of barrier material and polymer material are known. These composites are typically formed by depositing alternating layers of barrier material and polymer material, such as by vapor deposition. If the polymer layers are deposit...

AI Technical Summary

Benefits of technology

The present invention provides an edge-sealed barrier film composite that includes at least one initial barrier stack adjacent to a substrate, the barrier stack comprising at least one decoupling layer and at least one barrier layer, wherein the decoupling layer has an area greater than the barrier layer. The composite can be used to encapsulate environmentally sensitive devices, such as organic light emitting devices, liquid crystal displays, and thin film batteries. The composite provides improved protection against environmental factors and can be made using various methods and materials.

Problems solved by technology

The lateral diffusion rate of moisture and oxygen is finite, and this will eventually compromise the encapsulation.

However, this decreases the area of the substrate which is usable for active environmentally sensitive devices.

In addition, it only lessens the problem, but does not eliminate it.

A similar edge diffusion problem will arise when a substrate containing a multilayer, thin film barrier composite is scribed and separated to create individual components.

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