Vehicular organic light emitting diode (OLED) light panel

Abstract

Described herein is an organic light emitting diode (OLED) assembly (110), including an OLED structure and an OLED support structure configured to attach the OLED to a holder (120). 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 (220), one or more organic layers (230,240), a first adhesive layer (250), a metal layer (260), and a second adhesive layer (270). In embodiments, the flexible glass-based substrate (220) can be larger than the metal layer (260), providing an overhang structure (310).

Description

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

[0001] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 604,326, 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 is an organic light emitting diode (OLED) assembly, including 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. In embodiments, the flexible glass-based substrate can be larger than the metal layer, providing an overhang structure.

[0006] A first embodiment (1) is directed to a vehicular light, comprising an organic light emitting diode (OLED) panel, comprising one or more diode structures comprising acathode, an anode, and an organic light emitting semiconductor material interposed between the cathode and the anode; a luminary holder comprising a bonding surface comprising a material comprising a coefficient of thermal expansion of from 20e'6 / °C to 100e'6 / °C; and an OLED support structure comprising a flexible glass-based substrate comprising an overhang portion; 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 luminary holder, wherein the flexible glass-based substrate overhang portion extends from an edge of the metal layer to a perimeter edge of the flexible glass -based substrate, and wherein the luminary holder is configured to attach the OLED support structure to a vehicle.

[0007] In a second embodiment (2), the overhang portion according to the first embodiment (1) overhangs an entire perimeter of the metal layer.

[0008] In a third embodiment (3), the overhang portion according to the first embodiment (1) or the second embodiment (2) comprises a length according to the following equation: wmax= 174.5(a + 15.4)'0 65, wherein wmaxis the length of the overhang portion, and a (10'6 / °C) is the coefficient of thermal expansion of the holder.

[0009] In a fourth embodiment (4), the overhang portion according to any one of embodiments (1) - (3) comprises a length of from 1 mm to 17 mm.

[0010] In a fifth embodiment (5), at least a portion of the flexible glass-based substrate according to any one of embodiments (1) - (4) comprises a radius of curvature that 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.

[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, the flexible glass-based substrate according to any one of embodiments (1) - (6) comprises an elastic modulus of from 70 GPa to 90 GPa.

[0013] In an eighth embodiment (8), the flexible glass-based substrate according to any one of embodiments (1) - (7) comprises a coefficient of thermal expansion of from 3e"6 / °C to 10 e'6 / °C.

[0014] In a ninth embodiment (9), the flexible glass-based substrate according to any one of embodiments (1) - (8) comprises a flat portion and a curved portion that conforms to a radius of curvature of a portion of the bonding surface of the luminary holder.

[0015] In a tenth embodiment (10), the second adhesive layer according to any one of embodiments (1) - (9) comprises a thickness of from 0.1 mm to 3 mm.

[0016] An eleventh embodiment (11) is directed to 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 luminary holder comprising a bonding surface comprising a material comprising a coefficient of thermal expansion of from 20e'6 / °C to 100e'6 / °C; and an OLED support substructure comprising a flexible glass-based substrate comprising an overhang portion comprising a length of from 1 mm to 17 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 luminary holder, wherein the flexible glass-based substrate overhang portion extends from an edge of the metal layer to a perimeter edge of the flexible glass-based substrate, and wherein the luminary holder is configured to attach the OLED support structure to a vehicle.

[0017] In a twelfth embodiment (12), the overhang portion according to the eleventh embodiment (11) is configured to overhang a perimeter of the metal layer.

[0018] In a thirteenth embodiment (13), the overhang portion according to the eleventh embodiment (11) or the twelfth embodiment (12) is configured to prevent first adhesive overflow.

[0019] In a fourteenth embodiment (14), at least a portion of the flexible glass-based substrate according to any one of embodiments (11) - (13) comprises a radius of curvature that 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.

[0020] In a fifteenth embodiment (15), the flexible glass-based substrate according to any one of embodiments (1) - (14) comprises athickness of from 0.1 mm to 0.3 mm.

[0021] A sixteenth embodiment (16) is directed to 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 luminary holder comprising a bonding surface comprising a material comprising a coefficient of thermal expansion of from 20e'6 / °C to 100e'6 / °C; and an OLED support structure comprising a flexible glass-based substrate comprising an elastic modulus of from70 GPa to 90 GPa and an overhang portion comprising a length of from 1 mm to 17 mm and free of any wrinkles having a height of greater than or equal to 0.1 mm; and an adhesive layer that bonds the OLED support structure to the bonding surface of the luminary holder, wherein the flexible glass-based substrate overhang portion extends from an edge of the metal layer to a perimeter edge of the flexible glass-based substrate, and wherein the luminary holder is configured to attach the OLED support structure to a vehicle.

[0022] In a seventeenth embodiment (17), at least a portion of the flexible glass-based substrate according to the sixteenth embodiment (16) comprises a radius of curvature that 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.

[0023] In an eighteenth embodiment (18), the flexible glass-based substrate according to the sixteenth embodiment (16) or the seventeenth embodiment (17) comprises a thickness of from 0.1 mm to 0.3 mm.

[0024] In a nineteenth embodiment (19), the OLED support structure according to any one of embodiments (16) - (18) further comprises one or more organic layers, an additional adhesive layer, and a metal layer; and wherein the overhang portion is configured to prevent adhesive overflow of the additional adhesive layer.

[0025] In a twentieth embodiment (20), the length of the overhang portion according to any one of embodiments (16) - (19) ranges from 2 mm to 10 mm.

[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 togetherwith the description serve to explain the principles and operation of the claimed subject mater.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 a wrinkling phenomenon.

[0034] FIG. 5 is a plot showing the dependency of wrinkling onset to the coefficient of thermal expansion of an OLED assembly holder according to embodiments of the disclosure.

[0035] The foregoing summary, as well as the following detailed description of certain inventive techniques, will be beter 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

[0036] 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.

[0037] 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 containingcomponents 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.

[0038] 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.

[0039] 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 not intended 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.

[0040] 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.

[0041] As used herein, the meaning of “room temperature” can include a temperature of from 15 °C to 30 °C.

[0042] 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 micro structure 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.

[0043] 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.

[0044] 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 a vehicle (e.g., a car, a small truck, a motorcycle, a sport-utility vehicle, a cross-over vehicle, a tractor-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 micro-transport vehicle, or the like). These OLED structures comprise an OLED lighting device coupled to a holder, and the holder coupled to any suitable vehicle.

[0045] 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 glassbased substrate, intermediate layers, support layers, and adhesives contribute to successful implementation of flexible OLED panels for vehicular lighting applications.

[0046] 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.

[0047] 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 luminary holder 120. In embodiments, luminaryholder 120 can be a curved luminary holder 120. The OLED panel 110 is discussed in further detail below. The luminary holder 120 can have any shape suitable for attachment to and light display from an automobile or any vehicle. In embodiments, the 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 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 luminary holder 120 can have a hybrid flat and curved shape. In such embodiments, the 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.

[0048] The 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 luminary holder 120 can comprise one or more attachment clips 140 configured to lock the luminary holder 120 into place on the vehicle body. In embodiments, the 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 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 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 luminary holder 120.

[0049] Referring now to FIG. 2, depicted is an illustration showing the OLED panel 110 prior to bonding to the luminary holder 120. In embodiments, all or a portion of the 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.

[0050] 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 luminary holder 120 such that the second adhesive layer 270 bonds the OLED panel 110 to the luminary holder 120. For example, pressing the OLED panel 110 onto the luminary holder 120 can shape the OLED panel to conform to the shape of the luminary holder 120 and bond the OLED panel 110 to the 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.

[0051] 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 CTE values provided herein for adhesive layers and the holder 120 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).

[0052] In embodiments, the flexible glass-based substrate can have a thickness ranging from 0. 1 mm to 0.3 mm. For example, the flexible glass-based substrate can 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.

[0053] In embodiments, the thickness of the flexible glass-based substrate 220 can contribute to a sustainable radius of curvature for automotive 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.

[0054] In embodiments, when the flexible glass-based substrate 220 is shaped to conform to the luminary holder 120 the flexible glass-based substrate 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.

[0055] In embodiments, the flexible glass-based substrate 220 comprises 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 10e'6 / °C, from 6e" 6 / °C to 10e'6 / °C, from 7e’6 / °C to 10e’6 / °C, from 8e’6 / °C to 10e’6 / °C, from 3e6 / °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.

[0056] Joined components comprising different materials having significantly varied coefficients of thermal expansion can expand and / or contract at different rates during heating 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 glass-based substrate 220 having a CTE within the disclosed range can aid in (i) achieving and maintaining a maximum allowable principal stress of the flexible glass-based substrate 220 on an exterior surface 225 as described herein, (ii) reducing or preventing wrinkles as described herein, or (iii) both.

[0057] In embodiments of the present disclosure the flexible glass-based substrate 220 can have an elastic (Young’s) modulus ranging from 70 GPa to 90 GPa. Unless otherwise noted, the Young’s modulus values recited in this disclosure for glass-based substrates 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.” The elastic modulus can contribute to a sustainable radius of curvature for automotive and / or vehicular applications. For example, the elastic modulus of the flexible glass-based substrate 220 can determine the ability of the glass to maintain itscurved 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 (i) achieving and maintaining a maximum allowable principal stress of the flexible glass-based substrate 220 on an exterior surface 225 as described herein, (ii) reducing or preventing wrinkles as described herein, or (iii) both.

[0058] 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 comprises 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 luminary holder 120 can include a flat portion 130 and a curved portion 135. In embodiments, the flat portion 130 of the luminary holder 120 can have a radius of curvature ranging from 1,000 mm to infinity. In embodiments, the curved portion 135 of the 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 luminary holder 120 after shaping and bonding to the luminary holder 120.

[0059] In embodiments, the OLED panel can include 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 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.

[0060] As noted earlier, the OLED device can include 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 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 certain circumstances, this can be advantageous where additional components in the diode structure are employed to harvest the light escaping the cathode. Therefore, embodiments of the OLED device can include a cathode having a thickness from about 10 nm 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.

[0061] Referring now to FIG. 3, depicted is a cross-section illustration of an OLED panel 110 according to certain embodiments of the present disclosure. The OLED panel 110 includes 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 is 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 are 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.

[0062] Additionally, in embodiments, the OLED panel can include an overhang portion 310. For example, the overhang portion 310 can include a portion of the flexible glass-based substrate 220 extending beyond an edge 265 of the metal layer 260. In embodiments, the overhang portion 310 extends from an edge 265 of the metal layer 260 to a perimeter edge 226 of the flexible glass-based substrate 220. The overhang portion 310 can be susceptible towrinkling along the edge of the flexible glass-based substrate 220, which can be caused by compressive stress from CTE mismatches with adjacent layers. Once wrinkling onsets, the local stress can easily exceed the maximum stress limit that the reducing the overhang portion 310 can suppress.

[0063] In embodiments, such wrinkling can be suppressed by tailoring the length of the overhang portion 310 in the x-axis direction as exemplified in FIG. 3. In embodiments, the flexible glass-based substrate 220 can have an overhang portion 310 having a length I of from 1 mm to 17 mm, including subranges. As described herein, the overhang length I is measured inward from a particular edge of the flexible glass-based substrate 220 in a direction extending perpendicular to that edge. In embodiments, the length I of overhang portion 310 can be greater than or equal to 2 mm to prevent the first adhesive layer 250 from flowing beyond an outer edge 265 of the metal layer 260 and / or beyond outer edge 226 of glass-based substrate 220. In embodiments, the length I of overhang portion 310 can range from 2 mm to 17 mm, from 1 mm to 15 mm, from 2 mm to 16 mm, from 5 mm to 15 mm, from 1 mm to 16 mm, from 1 mm to 10 mm, from 2 mm to 15 mm, from 5 mm to 10 mm, from 1 mm to 12 mm, or from 2 mm to 10 mm.

[0064] In embodiments, the overhang portion 310 can be disposed along an entire perimeter of the OLED panel 110, though it need not be. For example, the overhang portion 310 can be disposed along atop edge 170 ofthe OLED assembly 100, a bottom edge 172 of the OLED assembly 100, a right edge of the OLED assembly 100 when viewed from the illuminated side of the OLED assembly 100, a left edge of the OLED assembly 100, or any combination thereof. At top edge 170 and bottom edge 172, it will be appreciated that length I would extend in the z-axis direction exemplified in FIG. 1.

[0065] As used herein, a “wrinkle” in a glass-based substrate is defined as a local deviation in curvature of the glass-based substrate that has a height (as shown in FIG. 4) of greater than or equal to 0.1 mm. As used herein, “wrinkling” in a glass-based substrate is defined as multiple local deviations in curvature of the glass-based substrate having a wavelength of (X, as shown in FIG. 4) of less than 200 mm and that each have a height (2A, as shown in FIG. 4) of greater than or equal to 0. 1 mm. Unless specified otherwise, the presence of a wrinkle or wrinkling on a glass-based substrate is evaluated at a temperate of -40 °C.

[0066] Wrinkling can be characterized as a buckling phenomenon, the onset of which can be determined by the potential energy balance according to deformation modes. Wrinkling can occur when the potential energy of the compressive force on a glass-based substrate (resulting from for example, a temperature change, bending forces resulting from attachment to the luminary holder 120, or both) exceeds the potential energy of the wrinkling (£>£cr). Wrinkles in the flexible glass-based substrate 220 can be observed when the compressive stress is dominantly imposed to the glass in the in-plane direction. FIG. 4 depicts the schematics of the deformation mechanism when the wrinkles take place, especially when a stiff and thin layer is bonded on a soft, thick and pre-strained substrate. Even without the prestrain, the wrinkles can occur in a thin glass overhang at low temperatures (e.g., up to -40 °C) due to at least the compressive stress induced by a CTE mismatch between the glass, the luminary holder adhesive layer 270, and the luminary holder. As shown in FIG. 4, the wrinkling can be described as having a wavelength (I) and a height (2A).

[0067] In embodiments, an overhang portion 310 having an overhang length I as described herein can be free of any wrinkles having a height of greater than or equal to 0.1 mm. In an overhang portion 310 having an overhang length I as described herein can be free of wrinkles having a height of greater than or equal to 0. 1 mm and a wavelength of 200 mm or less.

[0068] To suppress or prevent wrinkling in the flexible glass-based substrate 220, optimal lengths of the overhang portion 310 for a glass-based substrate 220 as described herein can be expressed by the following equation:Imax = 174.5(a + 15.4)-0 65, (1) wherein a is the CTE of the bonding surface 125 of the luminary holder 120 material, and / max is the maximum length of the overhang portion 310, and the flexible glass-based substrate 220 is assumed to have a maximum length along the y-axis direction (perpendicular to the direction that the overhang length I is measured, see FIG. 3) of 200 mm. As a non-limiting example, when the bonding surface 125 of the luminary holder 120 comprises a polycarbonate material having a CTE of 65e'6 / °C, a maximum overhang portion 310 length of 10 mm can suppress or prevent wrinkling. For embodiments with smaller edge lengths (less than 200 mm) the maximum overhang length lmaxmay be higher than that predicted by equation 1 while still avoiding buckling. Different edges may have different maximum allowable overhang lengths depending on the perpendicular lengths of those edges. Inembodiments, when the overhang length I is uniform around the circumference of the OLED panel 110, the edge having the longest length in a direction perpendicular to that which the overlength I is measured is used to determine the uniform overhang length I. In such cases, even if one of the edges is relatively short compared to the others, the overhang length I may well under that which is necessary to prevent buckling for that individual edge.

[0069] FIG. 5 is a graph 500 showing wrinkling onset in a glass-based substrate 220 as described herein as a function of the CTE of the bonding surface 125 of the luminary holder 120 material. Notably, in FIG. 5 the maximum overhang portion length decreases as the CTE of the luminary holder 120 material increases. Thus, the length of the overhang portion 310 can be tailored to various luminary holders 120 composed of various materials. In embodiments, the bonding surface 125 of the luminary holder 120 can comprise a material having a CTE of from 20e'6 / °C to 100e'6 / °C, including subranges. For example, the bonding surface 125 of the luminary holder 120 can comprise a material having a CTE ranging from 20e'6 / °C to 90c’6 / °C. from 20c’6 / °C to 80e’6 / °C, from 20c’6 / °C to 70c’6 / °C. from 20e6 / °C to 60e'6 / °C, from 20e’6 / °C to 50e’6 / °C, from 20e’6 / °C to 40e’6 / °C, from 30e’6 / °C to 100e’6 / °C, from 40e'6 / °C to 100e’6 / °C, from 50e’6 / °C to lOOe C, from 60e’6 / °C to 100e’6 / °C, from 70e’ 6 / °C to I00e’6 / °C, or from 80e’6 / °C to 100e’6 / °C.

[0070] 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 glassbased substrate 220 of the OLED panel 110 can have a maximum principal stress less than or equal to 50 MPa.

[0071] In embodiments, to achieve a maximum principal stress of the flexible glass-based substrate at less than or equal to 75 MP, the length I of overhang portion 310 can be tailored to minimize the maximum principal stress as described herein. In embodiments, to achieve a maximum principal stress of the flexible glass-based substrate at less than or equal to 50 MP, the length I of overhang portion 310 can be tailored to minimize the maximum principalstress 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 substrate at less than or equal to 75 MP, the length I of overhang portion 310 can be tailored to minimize 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 substrate at less than or equal to 50 MP, the length I of overhang portion 310 can be tailored to minimize the maximum principal stress as described herein.

[0072] 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.

[0073] 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 stain gauge in accordance with ASTM E251-92 or predicted by 2D plane stain 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 luminary holder 120 with second adhesive layer 270. In embodiments, the maximum principal stress of the flexible glass-based substrate can occur in the overhang portion 310 of the glass-based substrate.

[0074] 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 comprise a particular feature, structure, or characteristic, but every embodiment may not necessarily comprise the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particularfeature, structure, 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, structure, or characteristic in connection with other embodiments whether or not explicitly described.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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 luminary holder comprising a bonding surface comprising a material comprising a coefficient of thermal expansion of from 20e'6 / °C to 100e'6 / °C; and an OLED support structure comprising: a flexible glass-based substrate comprising an overhang portion; 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 luminary holder, wherein the flexible glass-based substrate overhang portion extends from an edge of the metal layer to a perimeter edge of the flexible glass-based substrate, and wherein the luminary holder is configured to attach the OLED support structure to a vehicle.

2. The vehicular light according to claim 1, wherein the overhang portion overhangs an entire perimeter of the metal layer.

3. The vehicular light according to claim 1 or claim 2, wherein the overhang portion comprises a length according to the following equation: wmax= 174.5(a + 15.4)-°65, wherein wmaxis the length of the overhang portion, and a (10'6 / °C) is the coefficient of thermal expansion of the holder.

4. The vehicular light according to any one of claims 1 - 3, wherein the overhang portion comprises a length of from 1 mm to 17 mm.

5. The vehicular light according to any one of claims 1 - 4, wherein at least a portion of the flexible glass-based substrate comprises a radius of curvature that 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.

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 flexible glassbased substrate comprises an elastic modulus of from 70 GPa to 90 GPa.

8. The vehicular light according to any one of claims 1 - 7, wherein the flexible glassbased substrate comprises a coefficient of thermal expansion of from 3e'6 / °C to 10 e'6 / °C.

9. The vehicular light according to any one of claims 1 - 8, wherein the flexible glassbased substrate comprises a flat portion and a curved portion that conforms to a radius of curvature of a portion of the bonding surface of the luminary holder.

10. The vehicular light according to any one of claims 1 - 9, wherein the second adhesive layer comprises a thickness of from 0.1 mm to 3 mm.

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 luminary holder comprising a bonding surface comprising a material comprising a coefficient of thermal expansion of from 20e'6 / °C to 100e'6 / °C; and an OLED support substructure comprising: a flexible glass-based substrate comprising an overhang portion comprising a length of from 1 mm to 17 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 luminary holder, wherein the flexible glass-based substrate overhang portion extends from an edge of the metal layer to a perimeter edge of the flexible glass-based substrate, and wherein the luminary holder is configured to attach the OLED support structure to a vehicle.

12. The vehicular light according to claim 11, wherein the overhang portion is configured to overhang a perimeter of the metal layer.

13. The vehicular light according to claim 11 or claim 12, wherein the overhang portion is configured to prevent first adhesive overflow.

14. The vehicular light according to any one of claims 11 - 13, wherein at least a portion of the flexible glass-based substrate comprises a radius of curvature that 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.

15. The vehicular light according to any one of claims 11 - 14, wherein the flexible glassbased substrate comprises a thickness of from 0.1 mm to 0.3 mm.

16. 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 luminary holder comprising a bonding surface comprising a material comprising a coefficient of thermal expansion of from 20e'6 / °C to 100e'6 / °C; and an OLED support structure comprising:a flexible glass-based substrate comprising an elastic modulus of from 70 GPa to 90 GPa and an overhang portion comprising a length of from 1 mm to 17 mm and free of any wrinkles having a height of greater than or equal to 0. 1 mm; and an adhesive layer that bonds the OLED support structure to the bonding surface of the luminary holder, wherein the flexible glass-based substrate overhang portion extends from an edge of the metal layer to a perimeter edge of the flexible glass-based substrate, and wherein the luminary holder is configured to attach the OLED support structure to a vehicle.

17. The OLED panel according to claim 16, wherein at least a portion of the flexible glass-based substrate comprises a radius of curvature that 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.

18. The OLED panel according to claim 16 or claim 17, wherein the flexible glass-based substrate comprises a thickness of from 0. 1 mm to 0.3 mm.

19. The OLED panel according to any one of claims 16 - 18, wherein the OLED support structure further comprises one or more organic layers, an additional adhesive layer, and a metal layer; and wherein the overhang portion is configured to prevent adhesive overflow of the additional adhesive layer.

20. The OLED panel according to any one of claims 16 - 19, wherein the length of the overhang portion ranges from 2 mm to 10 mm.

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