Reference is made to commonly assigned U.S. patent application Ser. No. 10/822,517 filed Apr. 12, 2004, by Yuan-Sheng Tyan et al, entitled “OLED Device With Short Reduction” the disclosure of which is herein incorporated by reference.
The present invention relates to electroluminescent devices, and more particularly, to thin-film electroluminescent device structures for improving light output.
The present invention relates to electroluminescent devices. Examples of electroluminescent devices include organic light emitting devices (OLED), polymer light emitting devices (PLED), and inorganic electroluminescent devices.
A typical prior art electroluminescent device comprises a transparent substrate, a transparent first electrode layer, a light-emitting element including at least one light-emitting layer, and a reflecting second electrode layer. Light is generated in the electroluminescent device when electrons and holes that are injected from the two electrodes flowing through the light-emitting element and generating light by either recombination or impact ionization. The light-emitting element can include several layers of materials including at least a light-emitting layer where the emitted light is generated. In the case of an OLED device, for example, the light-emitting element can include an electron injection layer, an electron transport layer, one or more light-emitting layers, a hole transport layers, and a hole injection layer. One or several of these layers can be combined or eliminated and additional layers such as electron or hole blocking layers can be added. Most frequently, the first electrode layer is the anode and the second electrode layer is the cathode.
The light-emitting material has an index of refraction larger than that of the air and most frequently there is also one or more layers between the light emitting layer and air having index of refraction smaller than that of the light-emitting layer but larger than that of air. As the light travels from a higher index layer into a lower index layer total internal reflection can take place, the totally internal reflected light cannot transmit into the lower index layer and is trapped in the higher index layer. In the case of an OLED device, for example, the light emitting layer typically has an index of refraction of 1.7 to 1.8; the transparent electrode layer has an index of about 1.9, and the substrate has an index of about 1.5. Total internal reflection can take place at the transparent electrode/substrate interface. The fraction of the light from the light-emitting layer arriving at this interface with larger than critical angle from the normal is trapped within the organic layers and the transparent electrode layer and eventually absorbed by the materials in these layers or exited at the edges of the OLED device serving no useful functions. This fraction of light has been referred to as the organic-mode of light. Similarly, total internal reflection can take place at the substrate/air interface. The fraction of light arriving at this interface with larger than critical angle from the normal is trapped within the substrate, the transparent electrode layer, and the organic layers and eventually absorbed by the materials in the device or exited at the edges of the OLED device serving no useful function. This fraction of light has been referred to as the substrate-mode of light. It has been estimated that more than 50% of light generated by the light-emitting layer ends up as the organic mode of light, more than 30% ends up as the substrate mode of light, and less than 20% of light from the light-emitting layer can actually be outputted into the air and become useful light. The 20% of generated light that actually emits from the device has been referred to as the air-mode of light. Light trapping due to total internal reflection thus decreases drastically the output efficiency of electroluminescent devices.
Various techniques have been suggested to increase the efficiency of the thin-film electroluminescent devices by reducing the light trapping effect and allow the substrate-mode and organic-mode of light to emit from the device. These attempts are described in the references in detail and are included here by reference: U.S. Pat. Nos. 5,955,837, 5,834,893; 6,091,195; 6,787,796, 6,777,871; U.S. Patent Application Publication Nos. 2004/0217702 A1, 2005/0018431A1, 2001/0026124 A1; WO 02/37580 A1, WO02/37568 A1.
In general, these attempts all provide an enhancement structure that can change the direction of light such that some of the light that would have been trapped because of total internal reflection can emit into the air. Most of the enhancement structures, however, are placed on the outside surface of the transparent substrate opposite to the surface where the electroluminescent device is disposed. These enhancement structures can only access the air-mode light and the substrate-mode light since the organic-mode of light never reaches these structures. Since the organic-mode light constitute about half of the light generated, these enhancement structures are not very effective in enhancing the output of the electroluminescence device. To effectively improve the extraction of all three modes of light, the enhancement structure has to be placed close to the transparent electrode. For a bottom emitting structure that the present invention relates to, placing the enhancement structure close to the transparent electrode means the enhancement structure has to be placed inside the electroluminescent device between the transparent electrode and the substrate. Constructing this internal enhancement structure presents difficult technical challenges, however, since thin-film electroluminescent devices are very delicate. Placing the enhancement structure inside the device structure can cause many undesirable consequences including totally shorting out the devices. Although there have been suggestions of internal enhancement structures, no practical device structure have been described in the prior art that resulted in effective enhancement of light extraction efficiency.
The present invention provides electroluminescent devices with improved light extraction efficiency and methods for fabricating the devices.
In one embodiment of the present invention, an electroluminescent device comprises a transparent substrate, a securing layer, a light scattering layer, an electroluminescent unit including a transparent electrode layer, a light-emitting element including at least one light-emitting layer, and a reflecting electrode layer in that order, wherein the light scattering layer includes one monolayer of inorganic particles having an index of refraction larger than that of the light emitting layer and wherein the securing layer holds the inorganic particles in the light scattering layer.
In another embodiment of the present invention, an electroluminescent device comprises a transparent substrate, a securing layer, a light scattering layer, a surface smoothing layer, an electroluminescent unit including a transparent electrode layer, a light-emitting element including at least one light-emitting layer, and a reflecting electrode layer in that order, wherein the light scattering layer includes one monolayer of inorganic particles having an index of refraction larger than that of the light-emitting layer and wherein the securing layer holds the inorganic particles in the light scattering layer.
The present invention has the advantage that it increases the light output of an electroluminescent device; it further has the advantage that the device can be fabricated practically at low cost.
The present invention is described below with respect to OLED devices. It should be understood, however, that the same or similar can also be applied to polymer light emitting devices (PLED) and inorganic electroluminescent devices.
Referring to
Referring to
Since scattering layer 14 includes scattering particles of ellipsoidal or irregular shapes, the interface between scattering layer 14 and transparent electrode layer 16 may not be smooth. There can exist various gaps between the individual scattering particles in scattering layer 14 and between scattering particles and transparent electrode layer 16. An aspect of the present invention is that securing layer 12 contacts conformingly the surfaces of the scattering particles in scattering layer 14. Securing layer 12 fills most of the voids between the scattering particles in scattering layer 14 and most of the gaps between the scattering particles and transparent electrode layer 16. Securing layer 12 is preferably made from a securing material 12a that is in a liquid form or is pliable and during the process of fabrication spreads across the surface of light scattering layer 14 to form securing layer 12. Preferred materials for securing layer 12 include UV curable or heat curable polymeric materials including polyurethanes, epoxies, polyesters, acrylates, or acrylics and pressure sensitive adhesive materials. Securing material 12a can be a polymer precursor material and the polymerization to form securing layer 12 can be achieved using UV radiation or heat.
As light generated from light-emitting layer 25 in light-emitting element 18 transmits through transparent electrode layer 16, it impinges upon scattering layer 14 and becomes scattered. Some of the generated light that would have been trapped due to total internal reflection at the transparent electrode 16/substrate 10 interface or the substrate 10/air interface is scattered into a smaller than critical angle and is now able to emit into the air. Because the index of refraction of the scattering particles in scattering layer 14 is higher than that of light-emitting layer 25, the air mode, the substrate mode, and the organic mode of light can all penetrate into scattering layer 14 and be scattered effectively. The proximity of the scattering particles to transparent electrode layer 16 also ensures good light penetration and good scattering efficiency even in places where there is a gap between a scattering particle and transparent electrode layer 16 and securing layer 12 fills the gap. The output efficiency of OLED device 200 can be further improved by choosing a securing layer 12 having an index of refraction less than or equal to that of substrate 10 so that light scattered by scattering layer 14 into securing layer 12 suffers less internal reflection loss at securing layer 12/substrate 10 interface or at substrate 10/air interface.
Substrate 10 is transparent to the emitted light. It can be rigid or flexible and it can comprise materials such as glass or plastic. Transparent electrode layer 16 is most preferably a conductive transparent oxide layer including indium-tin oxide, indium-zinc oxide, tin-oxide, aluminum-zinc oxide, and cadmium-tin oxide. Material for reflecting electrode layer 20 is selected from Ag, Au, Al, or alloys thereof, most preferably is selected from Ag or alloys of Ag.
a) providing a carrier 30 having at least one smooth surface;
b) disposing a scattering layer 14 including a monolayer of scattering particles over the smooth surface of carrier 30;
c) providing a substrate 10 in relative position to carrier 30 and dispensing a quantity of a securing material 12a between substrate 10 and carrier 30;
d) engaging substrate 10 and securing material 12a to form securing material 12a into a securing layer 12 between substrate 10 and scattering layer 14;
e) separating substrate 10 with the attached securing layer 12 and scattering layer 14 from carrier 30; and
f) forming an electroluminescent unit 15, including a transparent electrode layer 16, a light-emitting element 18 including at least one light-emitting layer 25, and a reflecting electrode layer 20, on light scattering layer 14.
Carrier 30 can be made of a glass, a metal, a polymer, or a ceramic. Carrier 30 can be rigid or flexible and is most preferably a flexible polymeric material. Carrier 30 can be in a roll form prior to any of the steps above and it can be cut into sheet form prior to any of the steps above.
In one preferred embodiment of the present invention, securing material 12a is a curable material in a compilable or liquid form and there includes a curing step between steps d and e above.
a) providing a carrier 30 having at least one smooth surface;
b) disposing a scattering layer 14 comprising a monolayer of scattering particles over the smooth surface of carrier 30;
c) providing a substrate 10 in relative position to carrier 30 and dispensing a quantity of a securing material 12a between substrate 10 and carrier 30;
d) engaging substrate 10 and securing material 12a to form securing material 12a into a securing layer 12 between substrate 10 and scattering layer 14;
e) separating substrate 10 with the attached securing layer 12 and scattering layer 14 from carrier 30;
f) providing a surface smoothing layer 40 over scattering layer 14; and
g) forming an electroluminescent unit 15 on light scattering layer 14.
OLED devices 200, 300, 400, 500, or 600 can be pixilated or segmented. They can be used as display device or an illuminating device. In the former case the OLED devices can be part of a passive matrix structure or an active matrix structure. In the latter case they can be part of a monolithic serial-connected structure as disclosed in U.S. Pat. No. 6,693,296.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
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