CN1139293A - 有机器件的钝化 - Google Patents

有机器件的钝化 Download PDF

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CN1139293A
CN1139293A CN96105465A CN96105465A CN1139293A CN 1139293 A CN1139293 A CN 1139293A CN 96105465 A CN96105465 A CN 96105465A CN 96105465 A CN96105465 A CN 96105465A CN 1139293 A CN1139293 A CN 1139293A
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organic assembly
passivation
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insulating material
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CN1092396C (zh
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T·B·哈维三世
F·苏
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Universal Display Corp
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Motorola Inc
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    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10KORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K50/00Organic light-emitting devices
    • H10K50/80Constructional details
    • H10K50/84Passivation; Containers; Encapsulations
    • H10K50/844Encapsulations
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B33/00Electroluminescent light sources
    • H05B33/02Details
    • H05B33/04Sealing arrangements, e.g. against humidity
    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10KORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K50/00Organic light-emitting devices
    • H10K50/80Constructional details
    • H10K50/84Passivation; Containers; Encapsulations
    • H10K50/842Containers
    • H10K50/8423Metallic sealing arrangements
    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10KORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K99/00Subject matter not provided for in other groups of this subclass
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making

Abstract

本发明涉及一种在支持基片上钝化有机器件的方法,该方法包括把一层低温沉积的绝缘薄膜覆盖在有机器件上,并且在该绝缘材料上密闭地封接一层无机材料层从而实质性地密封该有机器件。在一个典型的实施例中,该绝缘层是二氧化硅(SiO2),该无机材料层是一个金属外壳。

Description

有机器件的钝化
本发明是关于有机器件的并且专门关于被钝化的有机器件和钝化(passivation)的方法。
有机器件,尤其是有机光发射二极管(LEDs)及类似的有机器件,通常在阴极上使用一层活性金属来保证效率高的电子注入电极和低的工作电压。但是。活性金属受氧和湿度的影响,特别是在工作期间。金属的氧化限制了器件的寿命。通常需要密封来实现长期稳定性和长的工作寿命。使用了若干类型的密封,其中最常用的是例如金属等诸如此类的无机材料。
在有机器件的制造和钝化中的另一个问题是有机器件的有机层不能承受很高的温度(通常高于大约300℃)。在很多情况下,甚至接近有机层的临界(critical)温度,尤其是如果升高的温度被保持相对来说较长的时间,可以使有机材料退化并降低可靠性和/或工作寿命。
近来一种密封有机器件的工艺是用例如陶瓷或金属的无机材料来覆盖它们,从而实现密封。可是,有机器件对在陶瓷和金属的沉积中通常所需要的高温非常敏感。因此,为了符合低温标准,通常必须使用PECVD方法来沉积陶瓷或金属材料。使用这一密封方法的主要问题是在PECVD沉积的期间存在着对有机器件的辐射损坏的较大可能性。
因此,非常希望设计一种相对来说便宜而方便的密封有机器件的方法。
本发明的目的是提供一种新的和改进了的钝化有机器件的方法。
本发明的目的还在于提供一种新的和改进了的在较低的温度下钝化有机器件的方法。
本发明的另一个目的是提供一种新的和改进了的相对来说方便而又花钱不多就能实现的钝化有机器件的方法。
通过钝化被安置在支持基片上的有机器件部分地解决了以上问题及其它一些问题并实现了以上目的及其它一些目的,该钝化包括的步骤是:把一层低温沉积的绝缘(dielectric)薄膜覆盖在有机器件上,并且密封地在该绝缘材料上接合一层无机材料从而实质性地密封该有机器件。
在一个典型的实施例中,该绝缘层是SiO2而无机(材料)层是金属外壳。在一些实施例中,可以在金属外壳内配置吸气剂材料来除出剩余的氧或湿气并且除去渗入的少量(氧或湿气),从而进一步增加了该有机器件的寿命。
参照附图,其中对于所有不同的外形(view),同样的符号表示同样的部件:
图1是有机光发射二极管的简化的剖面图;并且
图2是说明根据本发明的钝化方法的一个有机光发射二极管阵列的简化的剖面图。
具体地,参照图1,在这个具体的实施例中,基片10被表示出,它是某种光学洁净(clear)材料,例如是玻璃、石英、透明半导体材料或诸如此类的材料。一个典型的有机光发射二极管12(LED)被安置在基片10上,通常是使用制造有机光发射二极管(LEDs)的诸方法中的任一种方法来直接在基片10上制造LED12。
在这个具体的例子中,LED12包括沉积在基片10的上表面上的一层透明导体材料14,该透明导体材料例如是铟—锡—氧(Indi-um-tin-oxide,即ITO)或诸如此类的材料。可以是任何方便的方法在导体层14的上表面沉积一层有机电致发光层16。有机电致发光层16相当于LED12的有源有机层并且可以包括从一层到几层的子层,如本技术领域的内行人所熟悉的那样。一个金属接触面18处于有机电致发光层16的上表面来用作LDE12的阴极。接触面18至少包括一层活性的、低功函数(work function)的金属的薄层,该金属如上所述易受在环境大气中的氧和湿度的影响,因此,必须被钝化来达到可靠性和合理水平的长的工作寿命。
在图2中表示了根据本发明的钝化一个或多个LDEs的方法。在图2中多个LEDs被表示成一个有机LED阵列20的形式。如本技术领域的内行人所知,例如是ITO的一层透明导体材料22处于基片23的上表面,该基片也是透明的并且可以是例如玻璃或诸如此类的材料。层22被排列成行并且在层22的行上形成多个LEDs。这些LEDs中的每一个的上面的金属接触部分24被连接到列,于是,阵列20中的LEDs的每一个被单独地寻址。
在这个具体实施例的第一步,用低温沉积的绝缘材料薄膜25覆盖或包封阵列20。低温沉积的绝缘材料薄膜的一个典型例子是二氧化硅(SiO2),它是通过在处于大约10-4Torr的包含氧(O2)的气体环境中蒸发一氧化硅(SiO)而被沉积的。一般来说,薄膜25的厚度依赖于被使用的LEDs的类型和有源层的厚度。但是,如果标准的LEDs被制造,一层具有在大约500埃(A)到1500埃的范围内的厚度的该薄膜对于完成所需要的功能是足够厚的。薄膜25为以下步骤提供了一些附加的保护。
然后,在薄膜上的阵列20上密封地接上金层外壳30或类似的不可渗透的罩(例如金属箔,诸如金属化聚酯之类的金属化聚合物薄膜)。在一个优选的实施例中,围绕阵列20的薄膜25的上表面上有一个金属图形(没有示出)并且于阵列20之上在该金属图形上配置有金属外壳30,这时该结构仍处于薄膜沉积步骤的10-4Torr的真空状态下。使用低温焊料密封在32处把金属外壳30密封在阵列20上。可以用于这一用途的一种典型的低温焊料是以铟为基本组分的焊料(indium based solder)。在某些具体的应用中,如果使用具有足够低的熔化温度的焊料,可以简单地将金属外壳30直接密封在基底23的表面处。为了此处公开的目的,应该注意能够得到具有70℃-117℃的熔化点的铟焊料。
如果要求或希望附加的保护,可以在金属外壳30的内部形成一层吸气剂(getter)材料的薄膜34,例如,该薄膜可以作为金属外壳30的衬层(lining)或作为在薄膜25的上表面之上的一层材料。通常地,使用例如是锂(Li)或镁(Mg)的低功函数金属作为吸气剂材料(a gettering material)来吸收在金属外壳30中的被吸收的和剩余的气体或密封之后渗入金属外壳30的少量气体。
通过把吸气剂薄膜34安装在金属外壳30之内,少量的渗入可以被吸收,使得在某些应用中可以用某种有机粘合剂将金属外壳30密封到薄膜25或诸如此类的薄膜之上。一般地,有机粘合剂不要求升高的温度,如果金属外壳30适当地被安装在薄膜25上,有机粘合剂密封层32的厚度为最小。
因此,依赖于应用和需要保护的量,可以把金属外壳30、绝缘材料薄膜25、吸气剂薄膜34和在密封处32的不同类型的密封材料的各种组合便利而又常规地包括在制造工艺中。应该注意,薄膜25与阵列20相比通常具有更低的渗透率并且金属外壳30基本上是不渗透的,因此,与用一层无机材料进行简单的包封的已有结构相比,根据本发明的整体结构具有更好的抗渗透能力。而且,因为薄膜25是在低温下被沉积的并且金属外壳30是在低温下被密封的,阵列20不会被损坏,也不会被降低性能,否则由于包封过程或成品的热循环会受到损坏。另外,与已有技术的方法与器件相比,本发明包括更便于制造的工艺。
我们已经表示和描述了本发明的具体实施例,其他的修改和改进对于本技术领域的内行人来说是显然的。因此,我们要求得到理解,本发明不局限于被表示了的特殊形式,在所附的权利要求中,我们要求包括不背离本发明的主旨与范围的所有修改。

Claims (10)

1.钝化有机器件的一种方法,特征在于有以下步骤:
提供了在支持基片上的有机器件;
把一层低温沉积的绝缘(dielectric)材料薄膜覆盖在该有机器件上;
在绝缘材料上密封地接合一层无机层从而实质性地密封该有机器件。
2.如权利要求1所述的钝化有机器件的方法,特征在于:用低温绝缘材料来覆盖该有机器件的步骤的进一步的特征在于通过在低压氧的环境中蒸发该绝缘材料来产生在该有机器件上的薄膜。
3.如权利要求2所述的钝化有机器件的方法,特征在于:蒸发绝缘材料的步骤的进一步的特征在于通过在低压氧的环境中蒸发一氧化硅(silicon monoxide)来产生在该有机器件上的一层二氧化硅(silicon dioxide)的薄膜。
4.如权利要求3所述的钝化有机器件的方法,特征在于在低压氧环境下的蒸发氧化硅(silicon oxide)来产生二氧化硅(sili-con dioxide)薄膜的步骤的进一步的特征是在大约10-4 Torr的含氧的气体环境下蒸发氧化硅。
5.根据权利要求1所述的钝化有机器件的方法,特征在于在绝缘材料上密闭封接无机材料层的步骤的进一步的特征是配给金属外壳并且在绝缘材料薄膜上密闭封接该金属外壳,以此来实质性地密封有机器件。
6.根据权利要求5所述的钝化有机器件的方法,特征在于在绝缘材料薄膜上密闭封接金属外壳的步骤的进一步的特征是在把有机器件保持在大约10-4Torr的气体环境下的同时将该金属外壳固定在绝缘材料薄膜上。
7.根据权利要求5所述的钝化有机器件的方法,特征在于密闭封接金属外壳的步骤的进一步的特征是使用低温焊料进行密封。
8.根据权利要求7所述的钝化有机器件的方法,特征在于使用低温焊料进行密封来密闭封接金属外壳的步骤的进一步的特征是使用以铟(indium)为基本成分的焊料。
9.如权利要求5所述的钝化有机器件的方法,进一步的特征在于在绝缘材料薄膜上密闭封接金属外壳之前沉积一层吸气剂材料,从而将吸气剂材料的层配置在金属外壳之内。
10.根据权利要求9所述的钝化有机器件的方法,特征在于在绝缘材料薄膜上密闭封接金属外壳的步骤的进一步的特征是使用有机粘合剂。
CN96105465A 1995-05-02 1996-04-25 钝化有机发光二极管的方法 Expired - Fee Related CN1092396C (zh)

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