Vehicular organic light emitting diode (OLED) light panel

Abstract

Described herein are organic light emitting diode (OLED) assemblies (110) comprising an OLED structure and an OLED support structure configured to attach the OLED to a curved holder (120). In embodiments, the OLED structure includes a cathode, an anode, and an organic light emitting semiconductor material interposed between the cathode and the anode. In embodiments, the OLED support structure includes a flexible glass-based substrate (220), one or more organic layers (230,240), a first adhesive layer (250), a metal layer (260), and a second adhesive layer (270) with a perimeter edge comprising a corner with a comer radius of from 1 mm to 25 mm.

Description

VEHICULAR ORGANIC LIGHT EMITTING DIODE (OLED) LIGHT PANELCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority of U.S. Provisional ApplicationNo. 63 / 604,320, filed on November 30, 2023, the content of which is relied upon and incorporated herein by reference in its entirety.FIELD OF THE DISCLOSURE

[0002] The present disclosure relates generally to vehicular lighting, organic light emitting diodes (OLEDs), OLED-based lighting devices and OLED-based vehicular devices. More particularly, the disclosure relates to light support structures, assemblies and elements for use with OLEDs.BACKGROUND

[0003] As vehicular manufacturing moves toward fully electric vehicles, energy consumption of the vehicles will need to be reduced and / or optimized to improve battery life and extend battery charge to cover greater distances.

[0004] Accordingly, there is need for high-efficiency OLED device configurations that can be manufactured with relatively low processing-related cost and high yields and conform to vehicular design and government regulations.SUMMARY OF THE DISCLOSURE

[0005] Described herein are organic light emitting diode (OLED) assemblies comprising an OLED structure and an OLED support structure configured to attach the OLED to a curved holder. In embodiments, the OLED structure comprises a cathode, an anode, and an organic light emitting semiconductor material interposed between the cathode and the anode. In embodiments, the OLED support structure comprises a flexible glass-based substrate, one or more organic layers, a first adhesive layer, a metal layer, and a second adhesive layer with a perimeter edge comprising a comer with a corner radius of from 1 mm to 25 mm.

[0006] A first embodiment (1) is directed to an vehicular light comprising an organic light emitting diode (OLED) panel, comprising one or more diode structures comprising a cathode, an anode, and an organic light emitting semiconductor material interposed between the cathode and the anode; a curved luminary holder comprising a bondingsurface; and an OLED support structure comprising a flexible glass-based substrate; one or more organic layers; a first adhesive layer; a metal layer; and a second adhesive layer that bonds the OLED support structure to the bonding surface of the curved luminary holder, the second adhesive layer comprising a perimeter edge comprising a comer with a comer radius of from 1 mm to 25 mm, wherein the curved luminary holder is configured to attach the OLED support structure to an automobile.

[0007] In a second embodiment (2), at least a portion of the flexible glass-based substrate according to the first embodiment (1) comprises a radius of curvature of from 100 mm to 500 mm.

[0008] In a third embodiment (3), the flexible glass-based substrate according to the first embodiment (1) or the second embodiment (2) comprises a flat portion comprising a minimum radius of curvature greater than 1,000 mm and a curved portion comprising a radius of curvature from 100 mm to 500 mm.

[0009] In a fourth embodiment (4), the flexible glass-based substrate according to any one of embodiments (1) - (3) comprises an elastic modulus of from 70 GPa to 90 GPa.

[0010] In a fifth embodiment (5), the flexible glass-based substrate according to any one of embodiments (1) - (4) comprises a coefficient of thermal expansion of from 3e" 6 / °C to 10e'6 / °C.

[0011] In a sixth embodiment (6), the flexible glass-based substrate according to any one of embodiments (1) - (5) comprises a thickness of from 0. 1 mm to 0.3 mm.

[0012] In a seventh embodiment (7), the one or more diode structures according to any one of embodiments (1) - (6) is interposed between the flexible glass-based substrate and the first organic layer.

[0013] In an eighth embodiment (8), the second adhesive layer according to any one of embodiments (1) - (7) comprises a thickness of from 0. 1 mm to 3 mm.

[0014] In a ninth embodiment (9), the comer radius according to any one of embodiments (1) - (8) ranges from 2 mm to 10 mm.

[0015] In a tenth embodiment (10), at least a portion of the flexible glass-based substrate according to any one of embodiments (1) - (9) comprises a radius of curvature that ranges from 100 mm to 500 mm, and wherein a maximum principal stress of the flexible glass-based substrate is less than or equal to 75 MPa.

[0016] An eleventh embodiment (11) is directed to an vehicular light, comprising an organic light emitting diode (OLED) panel, comprising one or more diode structurescomprising a cathode, an anode, and an organic light emitting semiconductor material interposed between the cathode and the anode a curved luminary holder comprising a bonding surface; and an OLED support structure comprising a flexible glass-based substrate comprising a thickness of from 0. 1 mm to 0.3 mm; one or more organic layers; a first adhesive layer; a metal layer; and a second adhesive layer that bonds the OLED support structure to the bonding surface of the curved luminary holder, the second adhesive layer comprising a perimeter edge comprising a plurality of comers each having a comer radius of from 1 mm to 25 mm, wherein the curved luminary holder is configured to attach the OLED support structure to an automobile.

[0017] In a twelfth embodiment (12), the flexible glass-based substrate according to the eleventh embodiment (11) comprises an elastic modulus of from 70 GPa to 90 GPa.

[0018] In a thirteenth embodiment (13), the flexible glass-based substrate according to either the eleventh embodiment (11) or the twelfth embodiment (12) comprises a flat portion and a curved portion comprising a radius of curvature of from 100 mm to 500 mm.

[0019] In a fourteenth embodiment (14), the comer radius of each comer according to any one of embodiments (11) - (13) ranges from 2 mm to 10 mm.

[0020] In a fifteenth embodiment (15), at least a portion of the flexible glass-based substrate according to any one of embodiments (11) - (14) comprises a radius of curvature that ranges from 100 mm to 500 mm, and wherein a maximum principal stress of the flexible glass-based substrate is less than or equal to 75 MPa.

[0021] A sixteenth embodiment (16) is directed to an organic light emitting diode(OLED) panel, comprising at least a diode structure comprising a cathode, an anode, and an organic light emitting semiconductor material interposed between the cathode and the anode; a curved luminary holder comprising a bonding surface; and an OLED support structure comprising a flexible glass-based substrate comprising a thickness of from 0. 1 mm to 0.3 mm and an elastic modulus of from 70 GPa to 90 GPa; one or more organic layers; a first adhesive layer; a metal layer; and a second adhesive layer that bonds the OLED support structure to the bonding surface of the curved luminary holder, the second adhesive layer comprising a perimeter edge comprising a comer with a comer radius of from 1 mm to 25 mm, wherein the curved luminary holder is configured to attach the OLED support stmcture to an automobile.

[0022] In a seventeenth embodiment (17), the flexible glass-based substrate according to the sixteenth embodiment (16) comprises a coefficient of thermal expansion of from 3e'6 / °C to 10e'6 / °C.

[0023] In an eighteenth embodiment (18), the comer radius according to either the sixteenth embodiment (16) or the seventeenth embodiment (17) ranges from 2 mm to 10 mm.

[0024] In a nineteenth embodiment (19), the flexible glass-based substrate according to any one of embodiments (16) - (18) comprises a flat portion and a curved portion comprising a radius of curvature of from 100 mm to 500 mm.

[0025] In a twentieth embodiment (20), at least a portion of the flexible glass-based substrate according to any one of embodiments (16) - (19) comprises a radius of curvature that ranges from 100 mm to 500 mm, and wherein a maximum principal stress of the flexible glass-based substrate is less than or equal to 75 MPa.

[0026] Additional features and advantages will be set forth in the detailed description which follows, and will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.

[0027] It is to be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework to understanding the nature and character of the claimed subject matter.

[0028] The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated into and constitute a part of this specification. The drawings illustrate the various embodiments described herein, and together with the description serve to explain the principles and operation of the claimed subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The following is a description of the figures in the accompanying drawings.The figures are not necessarily to scale, and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.

[0030] FIG. 1 is a schematic illustration of an OLED vehicular lighting assembly according to embodiments of the disclosure.

[0031] FIG. 2 is an illustration of an OLED vehicular lighting assembly according to embodiments of the disclosure.

[0032] FIG. 3 an illustration of an OLED vehicular lighting assembly according to embodiments of the disclosure.

[0033] FIG. 4 is a schematic illustration of an OLED assembly according to embodiments of the disclosure.

[0034] The foregoing summary, as well as the following detailed description of certain inventive techniques, will be better understood when read in conjunction with the figures. It should be understood that the claims are not limited to the arrangements and instrumentality shown in the figures. Furthermore, the appearance shown in the figures is one of many ornamental appearances that can be employed to achieve the stated functions of the apparatus.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0035] Additional features and advantages will be set forth in the detailed description which follows and will be apparent to those skilled in the art from the description, or recognized by practicing the embodiments as described in the following description, together with the claims and appended drawings.

[0036] As used herein, the term “and / or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and / or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.

[0037] In this document, relational terms, such as first and second, top and bottom, and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0038] Modifications of the disclosure will occur to those skilled in the art and to those who make or use the disclosure. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and notintended to limit the scope of the disclosure, which is defined by the following claims, as interpreted according to the principles of patent law, including the doctrine of equivalents.

[0039] For purposes of this disclosure, the term “coupled” (in all of its forms: couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature, or may be removable or releasable in nature, unless otherwise stated.

[0040] As used herein, the meaning of “room temperature” can include a temperature ranging from 15 °C to 30 °C.

[0041] As used herein, the term “glass-based” is meant to include any material made at least partially of glass, including glass and glass-ceramics. “Glass-ceramics” include materials produced through controlled crystallization of glass. One or more nucleating agents, for example, titanium oxide (TiO2), zirconium oxide (ZrO2), sodium oxide (Na2O), and phosphorus oxide (P2O5) may be added to a glass-ceramic composition to facilitate homogenous crystallization. In embodiments, a glass-based article or sheet can exhibit an amorphous microstructure and can be substantially free of crystals or crystallites. In other words, the glass-based article or sheet in these embodiments exclude glass-ceramic materials. In other embodiments, a glass-based article or sheet can be a glass-ceramic article or sheet.

[0042] Referring to the drawings in general and to FIG. 1 in particular, it will be understood that the illustrations are for the purpose of describing particular embodiments and are not intended to limit the disclosure appended claims thereto. The drawings are not necessarily to scale, and certain features and certain views of the drawings may be shown exaggerated in scale or in schematic form in the interest of clarity and conciseness.

[0043] Described in this disclosure are organic light emitting diodes (OLEDs), OLED assemblies for vehicular applications, and OLED-based lighting devices. The disclosure further details vehicular luminary holders, along with methods of making the same. More generally, the OLED structures disclosed herein offer a cost-reducing and energy efficient vehicular lighting alternative. Additionally, the OLED panels described herein can provide a solid-panel luminary appearance when affixed to an automobile, or any vehicle (e.g., a car, a small truck, a motorcycle, a sport-utility vehicle, a cross-over vehicle, atractor-trailer, a box truck, an all-terrain vehicle, a mass transit vehicle, a construction vehicle, an agricultural vehicle, a marine vehicle, a human-powered vehicle, a microtransport vehicle, or the like). These OLED structures comprise an OLED lighting device coupled to a holder, and the holder coupled to any suitable vehicle.

[0044] Also described herein are OLEDs on flexible glass-based substrates that can be shaped to conform to the contours of a vehicle to which the OLED panel is being attached. The disclosure further details how physical and geometric characteristics of the flexible glass-based substrate, intermediate layers, support layers, and adhesives contribute to successful implementation of flexible OLED panels for vehicular lighting applications.

[0045] There are various advantages associated with the OLED structures and assemblies of the disclosure. Embodiments of the OLED structures and assemblies disclosed herein address the need to provide cost-effective and energy efficient vehicular lighting that is viewable from a wide angle of viewing positions. In embodiments, the OLED structures and assemblies can provide vehicular illumination from behind the vehicle to either side of the vehicle. In embodiments, the OLED structures and assemblies can provide vehicular illumination at the front of the vehicle and / or to either side of the vehicle.

[0046] Referring now to FIG. 1, a schematic illustration of an OLED vehicular assembly 100 is provided according to embodiments of the disclosure. The illustrated OLED assembly 100 can comprise an OLED panel 110 and a curved luminary holder 120. The OLED panel 110 is discussed in further detail below. The curved luminary holder 120 can have any shape suitable for attachment to and light display from an automobile or any vehicle. In embodiments, the curved luminary holder 120 can comprise a flat portion 130 (for example, a portion having a radius of curvature greater than 1,000 mm, greater than 10,000 mm, or approaching infinity). In embodiments, instead of or in addition to a flat portion 130, the curved luminary holder 120 can comprise a curved portion 135 having a curved shape (for example, a shape having a radius of curvature ranging from about 1 mm to about 1,000 mm). In embodiments, the curved luminary holder 120 can have a hybrid flat and curved shape. In such embodiments, curved luminary holder 120 can have a flat portion 130 and a curved portion 135. In embodiments, the flat portion 130 can be positioned along a flat rear or front portion of a vehicle, and the curved portion 135 can wrap around a comer of the vehicle, for example,a taillight or a brake light positioned on the rear of the vehicle and wrapping around a rear comer of the vehicle to provide enhanced visibility from a variety of viewing angles, or a headlight positioned on the front of the vehicle and wrapping around a rear comer of the vehicle to provide enhanced visibility from a variety of viewing angles.

[0047] The curved luminary holder 120 can comprise a support structure (not shown) configured to add robustness to the holder under normal operating conditions, e.g., road vibration, off-road vibration, minor collisions, or the like. In embodiments, the curved luminary holder 120 can comprise one or more attachment clips 140 configured to lock the curved luminary holder 120 into place on a vehicle body. In embodiments, the curved luminary holder 120 can comprise one or more electrical contacts configured to provide electricity from the vehicle’s electrical system to the OLED panel 110. For example, the curved luminary holder 120 can comprise a female terminal 150 and a male terminal 160 configured to connect to an electrical lead conductively coupled to the vehicle’s electrical system. In embodiments, the curved luminary holder 120 can comprise a bonding surface 125. In embodiments, the bonding surface 125 can be configured to accept an adhesive (for example, the second adhesive layer 270) bonding the OLED panel 110 to the curved luminary holder 120.

[0048] Referring now to FIG. 2, depicted is an illustration showing the OLED panel 110 prior to bonding to the curved luminary holder 120. In embodiments, all of a portion of the curved luminary holder 120 can have a radius of curvature 210 ranging from about 1 mm to 1,000 mm, from about 50 mm to about 750 mm, or from about 100 mm to about 500 mm.

[0049] Additionally shown in FIG. 2 is a cross-sectional illustration of the OLED panel 110. The OLED panel 110 can comprise a flexible glass-based substrate 220, a first organic layer 230 and / or a second organic layer 240, a first adhesive layer 250, a metal layer 260, and a second adhesive layer 270. In embodiments, the OLED panel 110 can be pressed onto the curved luminary holder 120 such that the second adhesive layer 270 bonds the OLED panel 110 to the curved luminary holder 120. For example, pressing the OLED panel 110 onto the curved luminary holder 120 can shape the OLED panel to conform to the shape of the curved luminary holder 120 and bond the OLED panel 110 to the curved luminary holder 120. In embodiments, second adhesive layer 270 can comprise 3M™ Acrylic Plus Tape PT1100, or any similar adhesive tape with comparable mechanical properties.

[0050] In embodiments, second adhesive layer 270 can have a thickness ranging from 0. 1 mm to 3 mm. In embodiments, second adhesive layer 270 can comprise a material having an elastic modulus ranging from 0.01 MPa to 0.2 MPa In embodiments, second adhesive layer 270 can comprise a material having a CTE ranging from 50e'6 / °C to 800e" 6 / °C. Unless specified otherwise herein, CTE values provided herein are average values over a temperature range of 23 to 55°C, and are provided along a lengthwise direction (maximum linear dimension along a major surface thereof). Unless otherwise noted, CTE values are measured in accordance with ISO 11359-1 and ISO 11359-2 (2021).

[0051] In embodiments, as shown for example in FIG. 4, the second adhesive layer 270 can have a rectangular perimeter edge 430 with one or more comers 420 having a comer radius ranging from 1 mm to 25 mm. In embodiments, the curved comers 420 of the second adhesive layer 270 can have a comer radius ranging from 1 mm to 25 mm, including subranges. For example, the curved comers 420 can have a comer radius ranging from 2 mm to 25 mm, from 1 mm to 24 mm, from 2 mm to 24 mm, from 5 mm to 25 mm, from 1 mm to 20 mm, from 1 mm to 10 mm, from 2 mm to 15 mm, from 5 mm to 25 mm, from 1 mm to 15 mm, or from 2 mm to 10 mm.

[0052] As shown in FIG. 4, the comers of the OLED panel 110 can have various comer radii. The upper right comer 405 of panel can comprise a glass-based substrate 220 comer radius and an adhesive layer 270 comer radius within any of the ranges described herein. The upper left comer 415 of panel can comprise a glass-based substrate 220 comer radius and an adhesive layer 270 comer radius within any of the ranges described herein. The lower left comer 425 of panel can comprise a glass-based substrate 220 comer radius and an adhesive layer 270 comer radius within any of the ranges described herein. The lower right comer 435 of panel can comprise a glass-based substrate 220 comer radius and an adhesive layer 270 comer radius within any of the ranges described herein.

[0053] In embodiments, the second adhesive layer 270 can have a rectangular perimeter edge 430 with two comers 420 having a comer radius ranging from 1 mm to 25 mm, or within any of the ranges described above. In embodiments, the second adhesive layer 270 can have a rectangular perimeter edge 430 with three comers 420 having a comer radius ranging from 1 mm to 25 mm, or within any of the ranges described above. In embodiments, the second adhesive layer 270 can have a rectangular perimeter edge430 with four comers 420 having a comer radius ranging from 1 mm to 25 mm, or within any of the ranges described above.

[0054] In embodiments, the flexible glass-based substrate 220 can have a thickness ranging from 0.1 mm to 0.3 mm, including subranges. For example, the flexible glassbased substrate have a thickness ranging from 0.1 mm to 0.25 mm, from 0. 1 mm to 0.2 mm, or from 0.1 mm to 0.15 mm.

[0055] In embodiments, the thickness of the flexible glass-based substrate 220 can contribute to a sustainable radius of curvature for vehicular and / or vehicular applications. For example, the thickness of the flexible glass-based substrate 220 can contribute to the OLED panel 110 maintaining a radius of curvature that ranges from 100 mm to 500 mm and a maximum principal stress less than or equal to 75 MP (or less than or equal to 50 MPa) at temperatures ranging from -40 °C to 85 °C. In embodiments, the thickness of the flexible glass-based substrate 220 can contribute to the OLED panel 110 maintaining a radius of curvature that ranges from 100 mm to 500 mm and a maximum principal stress less than or equal to 75 MP (or less than or equal to 50 MPa) at temperatures ranging from -40 °C to 85 °C for a period of at least 15 years after bonding OLED panel 110 to the curved luminary holder 120 with second adhesive layer 270.

[0056] In embodiments, when the flexible glass-based substrate 220 is shaped to conform to the curved luminary holder 120, the flexible glass-based substrate 220 is subjected to a bending stress that is influenced by the thickness of the flexible glass-based substrate 220. Thus, a minimum radius of curvature created during a shaping operation can be controlled as to not exceed a maximum allowable principal stress of the flexible glass-based substrate 220 on an exterior surface 225 as described herein.

[0057] In embodiments, the flexible glass-based substrate 220 can comprise a coefficient of thermal expansion (CTE) of from 3e'6 / °C to 10e'6 / °C. For example, the flexible glass-based substrate can have a CTE ranging from 4e'6 / °C to 10e'6 / °C, from 5e" 6 / °C to IOc’6 / °C. from 6c’6 / °C to IOc’6 / °C. from 7c’6 / °C to 1 c’6 / °C. from 8c’6 / °C to 10e’ 6 / °C, from 3e'6 / °C to 9e'6 / °C, from 3e'6 / °C to 8e'6 / °C, from 3e'6 / °C to 7e'6 / °C, from 3e" 6 / °C to 6e'6 / °C, or from 3e'6 / °C to 4e'6 / °C. The CTE of the flexible glass-based substrate 220 can be measured over the temperature range -50-300°C using a push-rod dilatometer in accordance with ASTM E228-11.

[0058] Joined components comprising different materials having significantly varied coefficients of thermal expansion can expand and / or contract at different rates duringheating and / or cooling. Accordingly, expansion and / or contraction rates can cause increased and detrimental stress and strain at bonding interfaces, resulting in excess fatigue and / or failure of the bonded layers, e.g., the OLED panel 110. A flexible glassbased substrate 220 having a CTE within the disclosed range can aid in achieving and maintaining a maximum allowable principal stress of the flexible glass-based substrate 220 on an exterior surface 225 as described herein.

[0059] In embodiments of the present disclosure, the flexible glass-based substrate 220 can have an elastic (Y oung’s) modulus ranging from 70 GPa to 90 GPa. Unless otherwise noted, the Young’s modulus values recited in this disclosure refer to a value as measured by a resonant ultrasonic spectroscopy technique of the general type set forth in ASTM El 11-97, entitled “Standard Test Method for Young's Modulus, Tangent Modulus, and Chord Modulus.” In embodiments, an elastic modulus within this range can contribute to a sustainable radius of curvature for vehicular and / or vehicular applications. For example, the elastic modulus of the flexible glass-based substrate 220 can influence the ability of the glass to maintain its curved shape without additional stress due to spring -back or inherent plasticity of the flexible glass-based substrate 220. Thus, the elastic modulus can aid in achieving and maintaining a maximum allowable principal stress of the flexible glass-based substrate 220 on an exterior surface 225 as described herein.

[0060] In embodiments, the flexible glass-based substrate can comprise a flat portion 130 that can have a minimum radius of curvature greater than 1,000 mm. In embodiments, the flexible glass-based substrate can comprise a curved portion 135 that can have a radius of curvature ranging from 100 mm to 500 mm. In embodiments, the flexible glass-based substrate can comprise a flat portion 130 that can have a minimum radius of curvature greater than 1,000 mm and a curved portion 135 that can have a radius of curvature ranging from 100 mm to 500 mm. Referring back to FIG. 1, the curved luminary holder 120 can comprise a flat portion 130 and a curved portion 135. In embodiments, the flat portion 130 of the curved luminary holder 120 can have a radius of curvature ranging from 1,000 mm to infinity. In embodiments, the curved portion 135 of the curved luminary holder 120 can comprise a radius of curvature ranging from 100 mm to 500 mm. In embodiments, the curved portion 135 of the flexible glass-based substrate 220 can have a radius of curvature conforming to the radius of curvature 210 of the curved luminary holder 120 after shaping and bonding to the curved luminary holder 120.

[0061] In embodiments, the OLED panel can comprise at least one diode structure comprising a cathode, an anode, and an organic light emitting semiconductor material interposed between the cathode and the anode (for example, an OLED device). In some embodiments, the OLED device and / or a plurality of OLED devices can be interposed between the flexible glass-based substrate 220 and the first organic layer 230. In embodiments, interposing the OLED device between the flexible glass-based substrate 220 and the first organic layer 230 can provide a moisture and oxygen barrier protecting the OLED device from moisture and oxygen degradation and failure. In embodiments including second organic layer 240, layer 240 can further contribute to protecting the OLED device from the deleterious effects of moisture and oxygen. Encapsulating the OLED device between the flexible glass-based substrate 220 and one or more organic layers (e.g., the first organic layer 230 and / or the second organic layer 240) can provide optimal protection from moisture and oxygen.

[0062] Referring now to FIG. 3, depicted is a cross-section illustration of an OLED panel 110 according to embodiments of the present disclosure. The OLED panel 110 can comprise the second adhesive layer 270, the metal layer 260, the first adhesive layer 250, the second organic layer 240, the first organic layer 230, and the flexible glass-based substrate 220. As described previously, the OLED device can be interposed between the flexible glass-based substrate 220 and the first organic layer 230. Notably depicted in FIG. 3, the metal layer 260, the first adhesive layer 250, the second organic layer 240, and the first organic layer 230 can be staggered in length extending beyond an outer edge 275 of the second adhesive layer 270. In embodiments, these staggered lengths provide encapsulation of the OLED device.

[0063] As noted earlier, the OLED device can comprise a diode structure. The anode can be a transparent conductive oxide (TCO), such as indium tin oxide (ITO), which is transparent or substantially transparent to light emitted by the organic light emitting semiconductor material. Further, the cathode can be any conductive material that has the appropriate work function to match the light emitting material. For example, the cathode can be Ag, Au, Al, Sn, Tm, Yb or bi-metallic materials, such as Ag:Al, Ca:Al, Eu:Yb, or Tm:Yb. The thickness of the cathode can be from about 70 nm to about 400 nm, from about 70 nm to about 300 nm, or from about 70 nm to about 200 nm. In some embodiments, when the thickness of the cathode is below about 70 nm, the device can become bi-directional as light can escape the cathode as well. Under certaincircumstances, this can be advantageous where additional components in the diode structure are employed to harvest the light escaping the cathode. Therefore, some embodiments of the OLED device can comprise a cathode having a thickness from about 10 run to about 70 nm, less than about 70 nm, or a thickness such that more than greater than 1% of the light emitted from OLED is emitted through the cathode. In some cases, the diode structure can have a thickness of about 2 microns or less. In some implementations, the diode structure can have a thickness of 2.0 microns or less, 1.5 microns or less, 1 micron or less or, in some cases, less than 0.5 microns.

[0064] In embodiments, the OLED panel can have a rectangular perimeter edge that can have comers with a comer radius ranging from 1 mm to 25 mm. Referring again to FIG. 1, the OLED panel 110 can comprise one or more curved comers 115. In embodiments, the curved comer(s) 115 can have a comer radius ranging from 1 mm to 25 mm, including subranges. For example, the curved comers 115 can have a comer radius ranging from 2 mm to 25 mm, from 1 mm to 24 mm, from 2 mm to 24 mm, from 5 mm to 25 mm, from 1 mm to 20 mm, from 1 mm to 10 mm, from 2 mm to 15 mm, from 5 mm to 25 mm, from 1 mm to 15 mm, or from 2 mm to 10 mm. In embodiments, additional layers in the OLED panel 110 can comprise comer radii within any of the ranges described above. For example, the flexible glass-based substrate 220, the second adhesive layer 270, the first adhesive layer 250, and the metal layer 260 can have one or more comers having comer radius ranging from 1 mm to 25 mm, or within any of the ranges described above. For example, in embodiments, glass-based substrate 220 can comprise comers 410 with comer radii within any of the ranges described above.

[0065] In embodiments, the flexible glass-based substrate 220 of the OLED panel 110 can have a maximum principal stress ranging from 25 MPa to 100 MPa, including subranges. For example, the flexible glass-based substrate 220 of the OLED panel 110 can have a maximum principal stress ranging from 25 MPa to 75 MPa, from 25 MPa to 60 MPa, from 30 MPa to 60 MPa, from 30 MPa to 50 MPa, from 50 MPa to 100 MPa, or from 50 MPa to 75 MPa. In embodiments, the flexible glass-based substrate 220 of the OLED panel 110 can have a maximum principal stress less than or equal to 75 MPa. In embodiments, the flexible glass-based substrate 220 of the OLED panel 110 can have a maximum principal stress less than or equal to 50 MPa. Such maximum principle stresses are applicable over the entire temperature range of -40°C to 85°C. That is, the maximumprinciple stress may be within the preceding range at each temperature within this temperature range.

[0066] In embodiments, to maintain a radius of curvature that ranges from 100 mm to 500 mm, and a maximum principal stress of the flexible glass-based at less than or equal to 75 MP, the comer radius of one or more comers of the second adhesive layer 270 can be tailored to reduce the maximum principal stress as described herein. In embodiments, to maintain a radius of curvature that ranges from 100 mm to 500 mm, and a maximum principal stress of the flexible glass-based at less than or equal to 50 MP, the comer radius of one or more comers of the second adhesive layer 270 can be tailored to minimize the maximum principal stress as described herein.

[0067] In embodiments, the maximum principal stress can be less than or equal to or equal to 75 MP at temperatures ranging from -40 °C to 85 °C. In embodiments, the maximum principal stress can be less than or equal to or equal to 50 MP at temperatures ranging from -40 °C to 85 °C. In embodiments, the maximum principal stress can be less than or equal to or equal to 75 MP for a period of at least 15 years after bonding OLED panel 110 to the curved luminary holder 120 with second adhesive layer 270. In embodiments, the maximum principal stress can be less than or equal to or equal to 50 MP for a period of at least 15 years after bonding OLED panel 110 to the curved luminary holder 120 with second adhesive layer 270.

[0068] As described herein, a maximum principal stress is an orthonormal stress on exterior surface 225 of flexible glass-based substrate 220 in a Cartesian coordinate system when shear stress is zero. Maximum principal stress can be measured using a strain gauge in accordance with ASTM E251-92 or predicted by 2D plane strain modeling. The maximum principal stress of the flexible glass-based substrate 220 is measured or calculated after flexible glass-based substrate 220 is bent and bonded to the curved luminary holder 120 with the second adhesive layer 270. In embodiments, the maximum principal stress of the flexible glass-based substrate can occur at or adjacent comers 420 of the second adhesive layer 270.

[0069] In embodiments, and not to be bound by theory, the maximum principal stress of the flexible glass-based substrate 220 is observed at the lowest temperature desired for vehicular applications due to the thermal contraction of at least the second adhesive layer 270. After the OLED panel 110 is bonded to the bonding surface 125 of the curved luminary holder 120, the thermal shrinkage of the curved luminary holder 120 isconsidered because it can induce an extra stress concentration at the comers of the second adhesive layer 270. The extra stress concentration can depend on the CTE of the curved luminary holder 120 and geometric parameters including the radius of curvature 210 of the curved luminary holder 120 (and incidentally, the OLED panel 110), a comer angle of the OLED panel 110, and particularly the flexible glass-based substrate 220 and / or the second adhesive layer 270, and the thickness and size of the curved luminary holder 120.

[0070] In embodiments, process limitations (for example, a chamfering process for OLED device encapsulation), can provide a minimum comer angle of 30° on the edge of the OLED panel 110 extending vertically from the metal layer 160 to the flexible glassbased substrate 220. This 30° comer angle can introduce a high stress concentration resulting from thermal contraction of the curved luminary holder 120. According to embodiments of the present disclosure, and as a non-limiting example, the comer radius of the second adhesive layer 270 can be greater than 8 mm at a 30° comer of the OLED panel 110 to achieve a maximum principal stress (for example a maximum principal stress of 50 MPa) as described herein. When the edge of the OLED panel 110 has greater comer angles (e.g., greater than 90°), it is believed that a lower comer radius minimum (e.g., 3.5 mm) can be used while still achieving the desired maximum principal stresses described herein (holding everything else constant). As used herein, the term “comer angle” refers to an interior angle (facing the referenced component) formed by extensions of flat edges meeting at the referred to comer. The comer angle refers to an angle formed when lines tangent to the meeting edges (outside of the comer regions) intersect.

[0071] Embodiments of the present disclosure are described in detail herein with reference to embodiments thereof as illustrated in the accompanying drawings, in which like reference numerals are used to indicate identical or functionally similar elements. References to “embodiments,” “an embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, stmcture, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, stmcture, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, stmcture, or characteristic in connection with other embodiments whether or not explicitly described.

[0072] The examples are illustrative, but not limiting, of the present disclosure. Other suitable modifications and adaptations of the variety of conditions and parameters normally encountered in the field, and which would be apparent to those skilled in the art, are within the spirit and scope of the disclosure.

[0073] As used in the claims, “comprising” is an open-ended transitional phrase. A list of elements following the transitional phrase “comprising” is a non-exclusive list, such that elements in addition to those specifically recited in the list may also be present. As used in the claims, “consisting essentially of’ or “composed essentially of’ limits the composition of a material to the specified materials and those that do not materially affect the basic and novel characteristic(s) of the material. As used in the claims, “consisting of’ or “composed entirely of’ limits the composition of a material to the specified materials and excludes any material not specified.

[0074] Where a range of numerical values is recited herein, comprising upper and lower values, unless otherwise stated in specific circumstances, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the claims be limited to the specific values recited when defining a range. Further, when an amount, concentration, or other value or parameter is given as a range, one or more preferred ranges or a list of upper preferable values and lower preferable values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper range limit or preferred value and any lower range limit or preferred value, regardless of whether such pairs are separately disclosed.

[0075] The present embodiment(s) have been described above with the aid of functional building blocks illustrating the implementation of specified functions and relationships thereof. The boundaries of these functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternate boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed.

[0076] It is to be understood that the phraseology or terminology used herein is for the purpose of description and not of limitation. The breadth and scope of the present disclosure should not be limited by any of the above-described exemplary embodiments, but should be defined in accordance with the following claims and their equivalents.

Claims

What is claimed is:1 . A vehicular light comprising: an organic light emitting diode (OLED) panel, comprising: one or more diode structures comprising a cathode, an anode, and an organic light emitting semiconductor material interposed between the cathode and the anode; a curved luminary holder comprising a bonding surface; and an OLED support structure comprising: a flexible glass-based substrate; one or more organic layers; a first adhesive layer; a metal layer; and a second adhesive layer that bonds the OLED support structure to the bonding surface of the curved luminary holder, the second adhesive layer comprising a perimeter edge comprising a comer with a comer radius of from 1 mm to 25 mm, wherein the curved luminary holder is configured to attach the OLED support stmcture to an automobile.

2. The vehicular light according to claim 1, wherein at least a portion of the flexible glass-based substrate comprises a radius of curvature of from 100 mm to 500 mm.

3. The vehicular light according to claim 1 or claim 2, wherein the flexible glass-based substrate comprises a flat portion comprising a minimum radius of curvature greater than 1,000 mm and a curved portion comprising a radius of curvature from 100 mm to 500 mm.

4. The vehicular light according to any one of claims 1 - 3, wherein the flexible glassbased substrate comprises an elastic modulus of from 70 GPa to 90 GPa.

5. The vehicular light according to any one of claims 1 - 4, wherein the flexible glassbased substrate comprises a coefficient of thermal expansion of from 3e'6 / °C to 10e'6 / °C.

6. The vehicular light according to any one of claims 1 - 5, wherein the flexible glassbased substrate comprises a thickness of from 0.1 mm to 0.3 mm.

7. The vehicular light according to any one of claims 1 - 6, wherein the one or more diode structures is interposed between the flexible glass-based substrate and the first organic layer.

8. The vehicular light according to any one of claims 1 - 7, wherein the second adhesive layer comprises a thickness of from 0.1 mm to 3 mm.

9. The vehicular light according to any one of claims 1 - 8, wherein the comer radius ranges from 2 mm to 10 mm.

10. The vehicular light according to any one of claims 1 - 9, wherein at least a portion of the flexible glass-based substrate comprises a radius of curvature that ranges from 100 mm to 500 mm, and wherein a maximum principal stress of the flexible glass-based substrate is less than or equal to 75 MPa.

11. A vehicular light, comprising: an organic light emitting diode (OLED) panel, comprising: one or more diode structures comprising a cathode, an anode, and an organic light emitting semiconductor material interposed between the cathode and the anode; a curved luminary holder comprising a bonding surface; and an OLED support structure comprising: a flexible glass-based substrate comprising a thickness of from 0.1 mm to 0.3 mm; one or more organic layers; a first adhesive layer; a metal layer; and a second adhesive layer that bonds the OLED support structure to the bonding surface of the curved luminary holder, the second adhesive layer comprising a perimeter edge comprising a plurality of comers each having a comer radius of from 1 mm to 25 mm, wherein the curved luminary holder is configured to attach the OLED support stmcture to an automobile.

12. The vehicular light according to claim 11, wherein the flexible glass-based substrate comprises an elastic modulus of from 70 GPa to 90 GPa.

13. The vehicular light according to claim 11 or claim 12, wherein the flexible glassbased substrate comprises a flat portion and a curved portion comprising a radius of curvature of from 100 mm to 500 mm.

14. The vehicular light according to any one of claims 11 - 13, wherein comer radius of each comer ranges from 2 mm to 10 mm.

15. The vehicular light according to any one of claims 11 - 14, wherein at least a portion of the flexible glass-based substrate comprises a radius of curvature that ranges from 100 mm to 500 mm, and wherein a maximum principal stress of the flexible glass-based substrate is less than or equal to 75 MPa.

16. An organic light emitting diode (OLED) panel, comprising: at least a diode stmcture comprising a cathode, an anode, and an organic light emitting semiconductor material interposed between the cathode and the anode; a curved luminary holder comprising a bonding surface; and an OLED support stmcture comprising: a flexible glass-based substrate comprising a thickness of from 0.1 mm to 0.3 mm and an elastic modulus of from 70 GPa to 90 GPa; one or more organic layers; a first adhesive layer; a metal layer; and a second adhesive layer that bonds the OLED support stmcture to the bonding surface of the curved luminary holder, the second adhesive layer comprising a perimeter edge comprising a comer with a comer radius of from 1 mm to 25 mm, wherein the curved luminary holder is configured to attach the OLED support stmcture to an automobile.

17. The OLED panel according to claim 16, wherein the flexible glass-based substrate comprises a coefficient of thermal expansion of from 3e'6 / °C to 10e'6 / °C.

18. The OLED panel according to claim 16 or claim 17, wherein the comer radius ranges from 2 mm to 10 mm.

19. The OLED panel according to any one of claims 16 - 18, wherein the flexible glassbased substrate comprises a flat portion and a curved portion comprising a radius of curvature of from 100 mm to 500 mm.

20. The OLED panel according to any one of claims 16 - 19, wherein at least a portion of the flexible glass-based substrate comprises a radius of curvature that ranges from 100 mm to 500 mm, and wherein a maximum principal stress of the flexible glass-based substrate is less than or equal to 75 MPa.

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