Patent Application
20170358763
The present disclosure relates to a flexible substrate and a method of manufacturing the same. More particularly, the present disclosure relates to a flexible substrate having high levels of flexibility, transparency, and conductivity to improve the quality of a flexible display device provided with the flexible substrate and a method of manufacturing the flexible substrate.
The display device market has experienced a rapid change in product trends, away from cathode ray tube (CRT) display devices towards flat panel displays (FPDs). Representative examples of FPDs are liquid crystal displays (LCDs), plasma display panels (PDPs), organic light-emitting diode (OLED) display devices, and the like, all of which are lighter, thinner, and easier to manufacture in larger sizes, as compared to CRT display devices.
Recently, advances in display technology are moving away from existing flat displays toward flexible displays, requiring higher mechanical flexibility. Future display devices are expected to have evolved into bendable, rollable, foldable, and stretchable structures. To realize flexible displays, all components of displays are required to be flexible. In particular, the improvement of the mechanical flexibility of transparent electrodes is most significant.
Transparent electrode materials are typically thin films having visible light transmittance of 80% or higher and sheet resistance of less than 1000 Ω/sq. A representative transparent electrode material that is currently most commonly used is indium tin oxide (ITO), comprised of 90% In2O3 and 10% SnO2.
ITO is suitably applicable to flat panel displays (FPDs), due to characteristics thereof, such as superior electrical conductivity, superior light transmittance, and ease of processing. However, the poor mechanical flexibility of ITO may cause problems when ITO is used in flexible displays. For example, at a radius of curvature (or bending) of 10 mm or less, cracks may be formed and electrical conductivity may be reduced.
In the related art, ITO was replaced by substitute transparent electrode materials, such as a metal mesh grid and Ag nanowires, to improve the flexibility of transparent electrodes. However, the application of substitute transparent electrode materials is not easy, due to complicated processes and compatibility with existing display processes. Therefore, a solution for using ITO transparent electrodes by improving the mechanical flexibility thereof is in demand.
Korean Patent Application Publication No. 10-2011-0135612 (Dec. 19, 2011)
Accordingly, the present disclosure has been made in consideration of the above problems occurring in the related art, and the present disclosure proposes a flexible substrate having high levels of flexibility, transparency, and conductivity to improve the quality of a flexible display device provided with the flexible substrate and a method of manufacturing the flexible substrate.
According to an aspect of the present disclosure, a flexible substrate may include: a flexible base; an indium tin oxide thin film disposed on the flexible base; and a number of nanoparticles discontinuously distributed in the indium tin oxide thin film.
The indium tin oxide thin film may contain Al-doped ZnO and In-doped ZnO therein.
The number of nanoparticles may be formed from a metal oxide selected from the group consisting of SiO2, TiO2, and Al2O3.
Surfaces of the nanoparticles may be exposed from a surface of the indium tin oxide thin film to be flush with the surface of the indium tin oxide thin film.
The flexible base may be formed from one selected from the group consisting of a thin glass sheet, a metal thin film, polyethylene terephthalate, polycarbonate, and polyimide.
The flexible base may be used as a cover substrate of an organic light-emitting diode device, and the indium tin oxide thin film may be used as a transparent electrode acting as an anode of the organic light-emitting diode device.
The flexible substrate may further include a barrier layer disposed between the indium tin oxide thin film and an organic light-emitting layer of the organic light-emitting diode device.
According to another aspect of the present disclosure, provided is a method of manufacturing a flexible substrate. The method may include: forming a number of nanoparticles discontinuously on a flexible base; depositing an indium tin oxide thin film on the flexible base on which the number of nanoparticles are disposed; and planarizing a surface of the indium tin oxide thin film deposited on the flexible base.
Forming the number of nanoparticles may include: providing the number of nanoparticles on the flexible base by spin coating; and post-processing the number of nanoparticles using heat or plasma after the spin coating.
Depositing the indium tin oxide on the flexible base may include: depositing the indium tin oxide thin film on the flexible base by sputtering or spin coating; and post-processing the deposited indium tin oxide thin film using heat or plasma.
The surface of the indium tin oxide thin film deposited on the flexible base may be planarized such that surfaces of the number of nanoparticles are exposed externally.
The number of nanoparticles may be formed from a metal oxide selected from the group consisting of SiO2, TiO2, and Al2O3.
According to the present disclosure, a number of nanoparticles having superior transparency and flexibility is discontinuously provided within a transparent thin film disposed on a base, thereby imparting a flexible substrate with high levels of flexibility, transparency, and conductivity.
In addition, according to the present disclosure, when the transparent thin film having the number of nanoparticles distributed therein is used as a transparent electrode acting as an anode of an OLED device, the transparent thin film can also act as an internal light extraction layer. Then, an internal light extraction layer that would otherwise be provided in a conventional OLED device as a separate layer from a transparent electrode can be omitted, thereby reducing the thickness of the OLED device. In addition, the reduced number of layers can simplify the manufacturing process.
Furthermore, according to the present disclosure, the flexible substrate can not only be used in the OLED device, but also in other flexible devices, such as a touch panel, electronic paper, a photovoltaic device, a light-emitting diode (LED), a quantum dot (QD) display device, and a lighting device, in which a transparent electrode is used. The flexible substrate can improve the quality of these flexible devices when used therein.
Hereinafter, a flexible substrate and a method of manufacturing the same according to exemplary embodiments will be described in detail with reference to the accompanying drawings.
In the following description, detailed descriptions of known functions and components incorporated herein will be omitted in the case that the subject matter of the present disclosure may be rendered unclear by the inclusion thereof.
As illustrated in
The flexible base 110 is a substrate supporting the ITO thin film 120 and the number of nanoparticles 130. When the flexible substrate 100 is used as a cover substrate of an OLED device, the flexible substrate 110 is disposed in a portion of the OLED device, i.e. on a surface of an OLED, through which light generated thereby exits, to allow light to pass therethrough, while serving as an encapsulation substrate to protect the ITO thin film 120, the number of nanoparticles 130, and the OLED from the external environment.
The flexible base 110 may be formed from a material having flexibility, such as a thin glass sheet, a metal thin film, polyethylene terephthalate (PET), polycarbonate (PC), and polyimide (PI). However, the flexible base 110 according to the exemplary embodiment is not limited to the above-stated materials, since the flexible base 110 may be formed from a range of other materials having flexibility.
The ITO thin film 120 is disposed on the flexible base 110. The number of nanoparticles 130 are distributed within the ITO thin film 120, thereby imparting the ITO thin film 120 with flexibility. The surfaces of the nanoparticles 130 are exposed from the surface of the ITO thin film 120. The exposed surfaces of the nanoparticles 130 are flush with the surface of the ITO thin film 120. The ITO thin film 120 may contain Al-doped ZnO (AZO) and In-doped ZnO (IZO).
As illustrated in
As illustrated in
According to this structure, when a forward voltage is induced between the ITO thin film 120 and the rear electrode 30, electrons migrate from the rear electrode 30 to the emission layer through the electron injection layer and the electron transport layer, while holes migrate from the ITO thin film 120 to the emission layer through the hole injection layer and the hole transport layer. The electrons and the holes that have migrated into the emission layer recombine with each other, thereby generating excitons. These excitons transit from an excited state to a ground state, thereby emitting light. The brightness of the emitted light is proportional to the amount of current that flows between the ITO thin film 120 and the rear electrode 30.
When the OLED is a white OLED used for lighting, the light-emitting layer may have a multilayer structure comprised of a high-molecular light-emitting layer emitting blue light and a low-molecular light-emitting layer emitting orange-red light, or may have a variety of other structures that emit white light. The organic light-emitting layer 20 may also have a tandem structure. In this case, a plurality of organic light-emitting layers 20 alternating with interconnecting layers may be provided.
A barrier layer 10 formed from a high-conductivity and high-transparency material is further provided between the ITO thin film 120 and the organic light-emitting layer 20. The barrier layer 10 serves to prevent indium (In) from diffusing from the ITO thin film 120 into the organic light-emitting layer 20.
The number of nanoparticles 130 are discontinuously distributed within the ITO thin film 120. The surfaces of the number of nanoparticles 130 are exposed from the surface of the ITO thin film 120 while being flush with the surface of the ITO thin film 120.
In general, porous materials are relatively more flexible and elastic than the other materials. According to the exemplary embodiment, the number of nanoparticles 130 are discontinuously distributed in a structure similar to porous materials, thereby imparting flexibility to the ITO thin film 120 having poor mechanical flexibility. The number of nanoparticles 130 may be formed from a metal oxide selected from among candidate metal oxides having superior transparency and flexibility, such as SiO2, TiO2, and Al2O3. When the number of nanoparticles 130 are formed from any one of the candidate metal oxides, the transparency of the ITO thin film 120 can be improved to be higher than that of the conventional ITO transparent electrode. However, the electrical conductivity of the ITO thin film 120 used as the transparent electrode of the OLED may be decreased, since the metal oxide is a nonconducting material. Thus, the type and amount of the number of nanoparticles 130 contained in the ITO thin film 120 may be controlled according to the specification of a display devices or a lighting device in which the OLED is used, such that the ITO thin film 120 exhibits maximal levels of conductivity, flexibility, and transparency.
Hereinafter, a method of manufacturing the flexible substrate according to the exemplary embodiment will be described with reference to
The method of manufacturing the flexible substrate according to the exemplary embodiment includes a nanoparticle forming step, an ITO deposition step, and a planarization step.
First, as illustrated in
In the nanoparticle forming step, the flexible base 110 may be formed from one selected from among a thin glass sheet, a metal thin film, polyethylene terephthalate (PET), polycarbonate (PC), and polyimide (PI).
As illustrated in
As illustrated in
When the planarization step is completed as described above, a flexible substrate 100 according to an exemplary embodiment is manufactured. The flexible substrate 100 manufactured as described above has high levels of flexibility and transparency, since the number of nanoparticles 130 having superior transparency and flexibility are discontinuously distributed within the ITO thin film 120.
The flexible substrate 100 can be used as a cover substrate of an OLED device. As illustrated in
The ITO thin film 120 having the number of nanoparticles 130 distributed therein is used not only as a transparent electrode acting as an anode of the OLED device but also acts as an internal light extraction layer of the OLED device. Then, an internal light extraction layer that would otherwise be provided in a conventional OLED device as a layer separate from a transparent electrode can be omitted, thereby reducing the thickness of the OLED device. In addition, the reduced number of layers can simplify the manufacturing process.
Although the flexible substrate 100 according to the exemplary embodiment has been described as being used as a cover substrate of an OLED device, the flexible substrate 100 can not only be used in the OLED device, but also in other flexible devices, such as a touch panel, electronic paper, a photovoltaic device, a light-emitting diode (LED), a quantum dot (QD) display device, and a lighting device, in which a transparent electrode is used. The flexible substrate 100 can improve the quality of these flexible devices when used therein.
The foregoing descriptions of specific exemplary embodiments of the present disclosure have been presented with respect to the drawings. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and obviously many modifications and variations are possible for a person having ordinary skill in the art in light of the above teachings.
It is intended therefore that the scope of the present disclosure not be limited to the foregoing embodiments, but be defined by the Claims appended hereto and their equivalents.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2014-0126852 | Sep 2014 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/KR2015/009400 | 9/7/2015 | WO | 00 |
