METHOD OF ENCAPSULATING AN ENVIRONMENTALLY SENSITIVE DEVICE

Abstract

Methods of encapsulating an environmentally sensitive device. The methods involve temporarily laminating a flexible substrate to a rigid support using a reversible adhesive for processing, reversing the reversible adhesive, and removing the device from the rigid support.

Description

This application is a continuation-in-part of U.S. application Ser. No. 11/068,356, filed Feb. 28, 2005, which is a divisional of U.S. application Ser. No. 09/966,163, filed Sep. 28, 2001, now U.S. Pat. No. 6,866,901, which is a continuation-in-part of U.S. application Ser. No. 09/427,138, filed Oct. 25, 1999, now U.S. Pat. No. 6,522,067, all of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

Many devices are subject to degradation caused by permeation of environmental gases or liquids, such as oxygen and water vapor in the atmosphere or chemicals used in the processing of the electronic product. The devices are usually encapsulated in order to prevent degradation.

Various types of encapsulated devices are known. For example, U.S. Pat. No. 6,268,695, entitled “Environmental Barrier Material For Organic Light Emitting Device And Method Of Making,” issued Jul. 31, 2001; U.S. Pat. No. 6,522,067, entitled “Environmental Barrier Material For Organic Light Emitting Device And Method Of Making,” issued Feb. 18, 2003; and U.S. Pat. No. 6,570,325, entitled “Environmental Barrier Material For Organic Light Emitting Device And Method Of Making”, issued May 27, 2003, all of which are incorporated herein by reference, describe encapsulated organic light emitting devices (OLEDs). U.S. Pat. No. 6,573,652, entitled “Encapsulated Display Devices”, issued Jun. 3, 2003, which is incorporated herein by reference, describes encapsulated liquid crystal displays (LCDs), light emitting diodes (LEDs), light emitting polymers (LEPs), electronic signage using electrophoretic inks, electroluminescent devices (EDs), and phosphorescent devices. U.S. Pat. No. 6,548,912, entitled “Semiconductor Passivation Using Barrier Coatings,” issued Apr. 15, 2003, which is incorporated herein by reference, describes encapsulated microelectronic devices, including integrated circuits, charge coupled devices, light emitting diodes, light emitting polymers, organic light emitting devices, metal sensor pads, micro-disk lasers, electrochromic devices, photochromic devices, microelectromechanical systems, and solar cells.

Generally, encapsulated devices can be made by depositing barrier stacks adjacent to one or both sides of the device. The barrier stacks typically include at least one barrier layer and at least one decoupling layer. There could be one decoupling layer and one barrier layer, there could be multiple decoupling layers on one side of one or more barrier layers, or there could be one or more decoupling layers on both sides of one or more barrier layers. The important feature is that the barrier stack has at least one decoupling layer and at least one barrier layer.

One embodiment of an encapsulated display device is shown in FIG. 1. The encapsulated display device 100 includes a substrate 105, a display device 110, and a barrier stack 115. The barrier stack 115 includes a barrier layer 120 and a decoupling layer 125. The barrier stack 115 encapsulates the display device 110, preventing environmental oxygen and water vapor from degrading the display device.

The barrier layers and decoupling layers in the barrier stack can be made of the same material or of a different material. The barrier layers are typically about 100-1000 Å thick, and the decoupling layers are typically about 1000-10,000 Å thick.

Although only one barrier stack is shown in FIG. 1, the number of barrier stacks is not limited. The number of barrier stacks needed depends on the level of water vapor and oxygen permeation resistance needed for the particular application. One or two barrier stacks should provide sufficient barrier properties for many applications, and three or four barrier stacks should be sufficient for most. The most stringent applications may require five or more barrier stacks.

The barrier layers can be deposited using a vacuum process, such as sputtering, chemical vapor deposition, plasma enhanced chemical vapor deposition, evaporation, sublimation, electron cyclotron resonance-plasma enhanced vapor deposition (ECR-PECVD), and combinations thereof. Suitable barrier materials include, but are not limited to, metals, metal oxides, metal nitrides, metal carbides, metal oxynitrides, metal oxyborides, and combinations thereof. The barrier layers can be graded composition barriers, if desired. Suitable graded composition barriers include, but are not limited to, those described in U.S. Pat. No. 7,015,640, which is incorporated herein by reference.

The decoupling layers can be deposited using vacuum processes, such as flash evaporation with in situ polymerization under vacuum, or plasma deposition and polymerization, or atmospheric processes, such as spin coating, ink jet printing, screen printing, or spraying. Suitable materials for the decoupling layer, include, but are not limited to, organic polymers, inorganic polymers, organometallic polymers, hybrid organic/inorganic polymer systems, and silicates.

Handling flexible substrates as discrete sheets during the encapsulation of environmentally sensitive devices is difficult. The discrete sheets must be positioned correctly in relationship to the various pieces of equipment for depositing barriers, devices, etc. For example, many of the deposition steps utilize masks which must be positioned accurately and reproducibly with respect to the substrate to obtain the proper coverage. In order to maintain the correct position during processing, the discrete sheets need to rest on a rigid substrate or be held tightly by a clamping system. However, it is not easy to retain a polymeric sheet by mechanical clamping because of the plastic nature (e.g., flow and distortion under applied stress) of a flexible substrate. Furthermore, the encapsulation process imparts heat to a polymeric substrate, which has two adverse effects. Plastic flow leading to distortion increases significantly with heating of the film and may become catastrophic when the Tg is reached. Although the coefficient of thermal expansion (TCE) may not seem important, it is significant in an x-y plane when the dimensions are several inches by several inches. Both effects can cause a sheet of film which is initially tightly held at a temperature at the onset of processing to relax and distort as processing heats the film. In addition, another common system cannot be used with vacuum deposition processes. In that arrangement, the film is positioned on a rigid plate that has channels connected to a vacuum system, and a vacuum pump is used to establish a vacuum under the film at the contact of the film with the plate that holds the film in place. The film is held by the atmospheric pressure on the exposed surface of the film. However, this cannot be done in a vacuum environment.

In addition, the use of barriers on flexible substrates in roll form presents a significant issue. No matter how they are used as substrates for devices, the operation of cutting the substrate to an appropriate size for the finished device exposes the cut edges to the permeation of contaminants. The proposed solutions for this problem generally require additional, precision manufacturing steps, or result in a construction that sacrifices some or all of the advantages of the flexible substrate.

Therefore, there is a need for a method of handling discrete sheets during encapsulation of environmentally sensitive devices.

SUMMARY OF THE INVENTION

The present invention meets this need by providing a method of encapsulating an environmentally sensitive device. The method comprises providing a flexible substrate; cutting the flexible substrate into a discrete sheet; temporarily laminating the flexible substrate to a rigid support using a reversible adhesive; optionally applying a first barrier stack adjacent to the flexible substrate, the first barrier stack comprising at least one barrier layer and at least one decoupling layer; applying the environmentally sensitive device adjacent to the flexible substrate; applying a second barrier stack adjacent to the environmentally sensitive device, the second barrier stack comprising at least one barrier layer and at least one decoupling layer, the environmentally sensitive device being encapsulated between the substrate and the second barrier stack, the substrate and the second barrier stack forming a seal, or between the first barrier stack and the second barrier stack, the first and second barrier stacks forming a seal; and reversing the reversible adhesive and removing the encapsulated environmentally sensitive device from the rigid support.

In another embodiment, the method comprises providing a flexible substrate in discrete sheet form; temporarily laminating the flexible substrate adjacent to a rigid support; applying a first barrier stack adjacent to the flexible substrate, the first barrier stack comprising at least one barrier layer and at least one decoupling layer; applying the environmentally sensitive device adjacent to the flexible substrate; applying a sheet of barrier material adjacent to the environmentally sensitive device to encapsulate the environmentally sensitive device between the first barrier stack and the sheet of barrier material, the first barrier stack and the sheet of barrier material forming a seal; and removing the encapsulated environmentally sensitive device from the rigid support.

By adjacent to, we mean next to, but not necessarily directly next to. There can be additional layers between two adjacent layers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram of an encapsulated environmentally sensitive device.

FIG. 2 is a diagram of an encapsulated environmentally sensitive device made according to one embodiment of the present invention.

FIG. 3 is a diagram of an encapsulated environmentally sensitive device made according to another embodiment of the present invention.

FIG. 4 is a diagram of an encapsulated environmentally sensitive device made according to another embodiment of the present invention.

FIG. 5 is a diagram of an encapsulated environmentally sensitive device made according to another embodiment of the present invention.

FIG. 6 is a diagram of an encapsulated environmentally sensitive device made according to another embodiment of the present invention.

FIG. 7 is a diagram of an encapsulated environmentally sensitive device made according to another embodiment of the present invention.

FIG. 8 is a diagram of an encapsulated environmentally sensitive device made according to another embodiment of the present invention.

FIG. 9 is a diagram of the structure of one embodiment of the first and second barrier stacks of the present invention.

FIG. 10 is a diagram of the structure of one embodiment of the first and second barrier stacks of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention uses an easily reversible lamination to hold discrete sheets of the flexible substrate on the rigid support. This provides a construction which is more compatible with current fabrication processes and equipment for environmentally sensitive devices such as OLEDs. The temperature uniformity is as good as that for glass, which allows a uniform deposition of the monomer on the discrete sheet of flexible substrate. The invention also includes a solvent-free debonding process, avoiding the complications associated with the use of solvents.

One advantage of supporting flexible substrates on a rigid support is that the sheet of flexible substrate is positioned once on the rigid support and held by an adhesive which is effective in a vacuum environment. Clamping systems developed for rigid materials, such as glass coating technologies, silicon wafer technologies, printed circuit board technologies, chips, etc, processed in vacuum environments can be used. Precise placement means can also be used. Bonding the flexible film to a rigid support provides superior heat transfer between the film and the support, allowing the support to be a more effective heat sink for unwanted process heating. Although the flexible film still has a TCE, careful selection of the adhesives and rigid supports can level the differences and so the potential expansion related issues. In addition, the adhesive is a plastic by nature (i.e., it can flow and distort when heated) and can take up thermal expansions.

Generally, the process of the present invention includes providing a flexible substrate; cutting the flexible substrate into a discrete sheet; temporarily laminating the flexible substrate to a rigid support using a reversible adhesive; optionally applying a first barrier stack adjacent to the flexible substrate, the first barrier stack comprising at least one barrier layer and at least one decoupling layer; applying the environmentally sensitive device adjacent to the flexible substrate; applying a second barrier stack adjacent to the environmentally sensitive device, the second barrier stack comprising at least one barrier layer and at least one decoupling layer, the environmentally sensitive device being encapsulated between the substrate and the second barrier stack, the substrate and the second barrier stack forming a seal, or between the first barrier stack and the second barrier stack, the first and second barrier stacks forming a seal; and reversing the reversible adhesive and removing the encapsulated environmentally sensitive device from the rigid support.

Suitable flexible substrates include, but are not limited to, polymer films, metals, and metal foils.

The flexible substrate can include one or more functional layers. Suitable functional layers include, but are not limited to, planarizing layers, adhesion promoting layers, scratch resistant layers, organic or inorganic layers, anti-reflective coatings, anti-fingerprint coatings, anti-static coatings, electrically conductive layers, electrode layers, and combinations thereof.

The flexible substrate can include a first barrier stack, or a first barrier stack can be added during processing. The first barrier stack can be applied using a variety of approaches, including but not limited to, processes which create an edge seal. Suitable edge sealing processes are described in U.S. Pat. No. 6,866,901, which is incorporated herein by reference.

Where a discrete sheet is to carry an array of devices, the first barrier stack can be created as an array of appropriately dimensioned regions with sealed edges. Although the masking of such an array provides a significant challenge, it is viable given the established masking capability currently in existence.

Environmentally sensitive devices include, but are not limited to, organic light emitting devices, liquid crystal displays, displays using electrophoretic inks, light emitting diodes, light emitting polymers, electroluminescent devices, phosphorescent devices, electrophoretic inks, organic solar cells, inorganic solar cells, thin film batteries, thin film devices with vias, integrated circuits, charge coupled devices, metal sensor pads, micro-disk lasers, electrochromic devices, photochromic devices, microelectromechanical systems, and solar cells, and combinations thereof.

The environmentally sensitive device is sealed between the substrate and the second barrier stack, or between a first barrier stack and a second barrier stack, which encapsulate the environmentally sensitive device. The second barrier stack can be applied using various processes which form an edge seal.

FIG. 2 shows encapsulated devices made according to one embodiment of the present invention. The flexible substrate 210 has a pre-applied first barrier stack 215. The individual layers of the barrier stacks are not shown. The flexible substrate 210 with the barrier stack 215 is temporarily laminated adjacent to the rigid support 220 using a reversible adhesive 225. Suitable reversible adhesives include, but are not limited to, heat activated adhesives, pressure sensitive adhesives, ultra-violet (UV) activated adhesives, or combinations thereof.

Heat activated adhesives are heated to activate the adhesive and to reverse it. Suitable heat activated adhesives include, but are not limited to, polyamides, ethylene-vinyl alcohol copolymers, ethylene-vinyl acetate copolymers, hydrocarbon resins, acrylics, and acrylic copolymers. The heat activated adhesives can include additional components which can modify the properties, including control of activation temperature, tack, melt viscosity, thermal stability, and adhesion to specific substrates. The additional components can desirably be selected so that the adhesive is free of components that will become migratory in a vacuum environment. The adhesive is desirably applied under conditions that do not entrain excessive air.

Pressure sensitive adhesives are based on controlling the strength of adhesion so that the pressure sensitive adhesives can adhere a first substrate upon which they are emplaced to a surface of a second substrate via contact under pressure, but with limited strength of adhesion so that they will allow the first substrate to be removed from the second substrate when the removal force exceeds the adhesive strength. When properly formulated, they have significantly higher adhesion to the first substrate so that they remain anchored to the first substrate when it is removed. The pressure sensitive adhesive could be applied to the rigid support, which would allow the removal of the encapsulated device on a flexible substrate without the need to clean an adhesive layer from the flexible substrate. For example, a supply of rigid supports could be prepared with a pre-applied pressure sensitive adhesive and a release sheet to prevent debris from attaching to the adhesive surface. These rigid supports could be fed to a flexible substrate alignment and attachment station. A supply of pre-cut flexible film substrates, either with or without a device, could be fed to the alignment and attachment station, positioned, and contacted to make the laminate. This type of pick and place station and process is used for placing chips onto boards.

UV activated adhesives provide an adhesive surface as applied. This allows the flexible substrate to be adhered to the rigid support. UV exposure results in loss of adhesion and therefore, release of the flexible substrate. Differing mechanisms can provide this result. One is to incorporate a component into the coating formulation that degrades in response to UV exposure thereby reducing and/or eliminating the adhesive properties of the coating. The other is to include a component in the coating that undergoes considerable cross-linking (polymerization) in response to UV exposure. Cross-linking and shrinkage accompanying cross-linking often result in a reduction in adhesion when the mechanisms involved do not include reacting with the surfaces in contact with the cross-linked coating. When initially applied, the coating has adhesive properties, but when exposed to UV radiation, cross-linking occurs, resulting in a loss of adhesive properties.

Another consideration is application method. One common approach involves heating the adhesive to form a melt that can be coated and “frozen” in place. An alternative is to dissolve the adhesive composition in a solvent and apply the mixture using conventional atmospheric coating processes. This process has the advantage of a superior ability to control the amount and uniformity of the adhesive deposited. It is also possible using conventional coating processes to apply adhesives as a blend of precursors that are reacted (partially cross-linked) after application to form an adhesive layer. Pressure sensitive acrylic and urethane based adhesives are commonly applied using this approach. Blends of reactive precursors can be essentially 100% solids. If the components are selected with low vapor pressures, they could be applied in a vacuum, if desired. Alternatively, they can be combined with a solvent for ease of application, and the solvent can be removed by evaporation after application and prior to initiation of the cure. The latter approach typically uses oligomeric components that are self-crosslinking to avoid issues with azeotropes formed between low molecular weight precursors and the solvent(s) used for coating.

Another consideration is the surface to be coated with the reversible adhesive. It is significantly easier to coat a web than a discrete sheet. However, handling barrier coated films requires particular care to avoid damage, accumulated debris, or premature exposure to environmental contaminants. Therefore, it may be desirable to apply the adhesive to the rigid support, helping to minimize handling of the barrier coated film.

The environmentally sensitive devices 230 are then applied adjacent to the first barrier stack 215 on the flexible substrate 210. The environmentally sensitive device can be applied by direct deposition, or it can be fabricated first and then placed adjacent to the first barrier stack.

A second barrier stack 235, which includes an edge seal, is applied adjacent to the environmentally sensitive devices 230, which are sealed between the first barrier stack 215 and the second barrier stack 235.

After the environmentally sensitive devices 230 are encapsulated, the adhesive 225 is reversed using a method appropriate to the type of reversible adhesive.

The individual encapsulated environmentally sensitive devices can be separated by cutting the flexible support 210 and first barrier stack 215. However, cutting through the first barrier stack can expose the various layers of the first barrier stack to contaminants.

Another method of making encapsulated environmentally sensitive devices is shown in FIG. 3. In this case, the flexible substrate 310 is temporarily laminated to the rigid support 320 using a reversible adhesive 325. The first barrier stack 315, which includes an edge seal, is applied after the flexible substrate 310 has been laminated adjacent to the rigid support 320. The individual layers of the barrier stacks are not shown. The first barrier stack 315 is applied over discrete areas of the flexible support 310, using masks, for example. The environmentally sensitive device 330 is encapsulated by the second barrier stack 335, which has an edge seal. The adhesive 325 can be reversed, and the rigid support 320 removed.

The individual encapsulated environmentally sensitive devices can be separated by cutting through the flexible substrate 310. In this embodiment, because the first barrier stack 315 was applied over discrete areas of the flexible substrate 310, the individual encapsulated environmentally sensitive devices can be separated without cutting through the first barrier stack 315. This avoids the damage that is often noted when barrier stack assemblies are cut.

FIG. 4 shows another method of making encapsulated environmentally sensitive devices. The flexible substrate 410 has a pre-applied first barrier stack 415. The individual layers of the barrier stacks are not shown. The flexible substrate 410 is cut into discrete sheets with dimensions appropriate to the environmentally sensitive device 430 to be applied. The discrete sheets of the flexible substrate 410 with the pre-applied first barrier stack 415 are temporarily laminated adjacent to the rigid support 420 with the reversible adhesive 425. The environmentally sensitive device 430 is applied adjacent to the first barrier stack 415, and encapsulated by the second barrier stack 435, which includes an edge seal. The adhesive can be reversed, and the rigid support 420 removed. The individual encapsulated environmentally sensitive devices are separated by the removal of the rigid support 420; separation does not require cutting. This approach allows the creation of an edge seal for the barrier stack edges exposed when the flexible substrate 410 and first barrier stack 415 were cut into discrete sheets.

The adhesive layer 425 can be replaced after each cycle, if desired. This helps to eliminate problems with contaminants and debris becoming trapped in the adhesive.

Another method is shown in FIG. 5. In this arrangement, the flexible support 510 is cut into discrete sheets having an appropriate size for environmentally sensitive device 530. The discrete sheets of the flexible substrate 510 are temporarily laminated to the rigid support 520 with the reversible adhesive 525. The first barrier stack 515, which has an edge seal, is deposited adjacent to the flexible substrate 510. The individual layers of the barrier stacks are not shown. The environmentally sensitive device 530 is fabricated adjacent to the first barrier stack 515, and the second barrier stack 535, which has an edge seal, encapsulates it. The adhesive 525 is reversed, and the rigid support 520 removed. The removal of the rigid support 520 separates the individual encapsulated environmentally sensitive devices; no cutting is necessary.

Still another method is shown in FIG. 6. The flexible support 610 has a pre-applied barrier stack 615. The flexible support 610 is cut into discrete sheets sized for the environmentally sensitive device 630. The flexible substrate 610 with the barrier stack 615 is temporarily laminated to the rigid support 620 using a reversible adhesive 625. The individual layers of the barrier stacks are not shown. In this arrangement, the barrier stack 615 faces the adhesive 625, rather than the flexible substrate 610 facing the adhesive 625. An optional functional layer 640, such as a scratch resistant layer, can be included over the barrier stack 615 and would serve as the interface between the barrier stack 615 and the adhesive 625. The environmentally sensitive device 630 is fabricated adjacent to the flexible support 610, and is encapsulated by the second barrier stack 635, which has an edge seal. This arrangement allows the second barrier stack 635 to protect the edges of the first barrier stack 615 which were exposed when the flexible substrate 610 and first barrier stack 615 were cut into discrete sheets.

Alternatively in FIGS. 2-6, the second barrier could be a sheet of a barrier material, such as a sheet of a metal or metal foil, which can be laminated over the environmentally sensitive device. FIG. 7 shows another method of making encapsulated environmentally sensitive devices. In this arrangement, the flexible substrate 710 includes a pre-applied three dimensional barrier 745. The flexible substrate 710 is temporarily laminated to the rigid support 720 using a reversible adhesive 725. The environmentally sensitive device 730 is fabricated adjacent to the flexible support 710. A second three dimensional barrier 750 encapsulates the environmentally sensitive device 730. The adhesive 725 can be reversed, and the rigid support 720 removed. The flexible substrate 710 can be cut to separate the individual encapsulated environmentally sensitive devices. One advantage of the three dimensional first and second barriers is that cutting the barriers does not compromise the barrier. A method of making a three dimensional barrier is described in U.S. application Ser. No. ______ (Attorney Docket No. VIT 0064 PA), filed concurrently herewith, entitled “Three Dimensional Multilayer Barrier and Method of Making”, which is incorporated by reference herein. Another method is shown in FIG. 8. In this embodiment, there is no barrier stack on the flexible substrate 810. For example, the flexible substrate could be a metal or metal foil. The flexible substrate 810 is temporarily laminated to the rigid support 820 using reversible adhesive 825. A second barrier stack 835 is applied adjacent to the environmentally sensitive device 830. The second barrier stack 835 can be applied by laminating a flexible film 840 with a pre-applied second barrier 835 using an adhesive 845. Other methods of lamination could be used including, but not limited to, using heat. A gettering material could be included between the adhesive 845 and the environmentally sensitive device 830.

A cover sheet could be laminated to an array of environmentally sensitive devices. The adhesive/sealant (and optional getter) could be patterned to surround each of the array of devices on the flexible substrate using a mask or a printing technique such as ink jet. Another method is the use of a layer of adhesive/sealant applied to the entire surface (the devices as well as the area between devices). A third method is to use pick and place equipment to apply individual covers to each of the devices. In this case, the adhesive/sealant could be applied as described in either of the first two approaches.

Alternatively, the second barrier 835 could be deposited adjacent to the environmentally sensitive device 830 using vacuum or atmospheric processes. In this case, the flexible film 840 and adhesive 845 would not be used.

There can be one or more first and/or second barrier stacks. The barrier stacks can include at least one decoupling layer and at least one barrier layer. For example, a suitable arrangement for the encapsulated environmentally sensitive device is shown in FIG. 9. The flexible substrate 910 is temporarily laminated to the rigid support 920 using a reversible adhesive 925. First barrier stacks 915 are adjacent to the flexible substrate 910. The environmentally sensitive device 930 is adjacent to the first barrier stacks 915. The second barrier stacks 935 are adjacent to the environmentally sensitive device 930. The first and second barrier stacks 915, 935 are made of alternating decoupling layers 940 and barrier layers 945. There are five first barrier stacks 915 of alternating decoupling layers and barrier layers, and seven second barrier stacks 935. In the second barrier stacks 935, the barrier layer adjacent to the environmentally sensitive device can be thicker than the other barrier layers, and the last decoupling layer (the top layer) can be thicker than the other decoupling layers, if desired. FIG. 9 shows only the order of the various layers; it does not show the edge seals for the barrier stacks.

Example 1

FIG. 10 shows one embodiment of a structure which was tested. The flexible substrate 1005 was polyethylene naphthenate. It had a hard coat layer (SDC Technology, crystal coat MP 101) 1010 on both sides. It also had pre-applied barrier stacks 1015 containing 5 sets of alternating layers of aluminum oxide 1020 and acrylate polymer 1025 and an additional aluminum oxide layer 1020. The flexible substrate and barrier stacks were temporarily laminated to the rigid glass support 1030 using a reversible adhesive (3M 668 Thermo Bond) 1035. A layer of calcium 1040, which is used to test barrier performance, was then deposited over the first barrier stacks 1015. The calcium test is described in Nisato et al., “Thin Film Encapsulation for OLEDs: Evaluation of Multi-layer Barriers using the Ca Test,” SID 03 Digest, 2003, p. 550-553, which is incorporated herein by reference. The second barrier stacks 1045 were then deposited. The second barrier stacks were 7 sets of alternating layers of aluminum oxide 1050 and acrylate polymer 1055. The first oxide layer (adjacent to the layer of calcium 1040) and the last polymer layer (the top layer) were thicker than the remaining layers. These samples had rather short lifetimes, typically about 25 hours at 60° C. and 90% RH. The best results were about 100 hours, but there was significant damage to the barrier coated flexible substrate.

The experiment was repeated by laminating the flexible substrate with the pre-applied barrier stacks to the rigid glass support. Three layers, a fast process aluminum oxide, acrylate polymer, and aluminum oxide were deposited on the barrier stacks prior to deposition and encapsulation of the Ca test patch. This was done to solve issues which were believed to be due to debris from shipping and/or handling of the flexible substrate and barrier stacks. This experiment showed excellent results, with about 90% of the Ca samples passing after 500 hours at 60° C. and 90% RH.

While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes in the compositions and methods disclosed herein may be made without departing from the scope of the invention, which is defined in the appended claims.

Claims

1. A method of encapsulating an environmentally sensitive device comprising:

providing a flexible substrate in discrete sheet form;

temporarily laminating the flexible substrate adjacent to a rigid support;

optionally applying a first barrier stack adjacent to the flexible substrate, the first barrier stack comprising at least one barrier layer and at least one decoupling layer;

applying the environmentally sensitive device adjacent to the flexible substrate;

applying a second barrier stack adjacent to the environmentally sensitive device, the second barrier stack comprising at least one barrier layer and at least one decoupling layer, the environmentally sensitive device being encapsulated between the substrate and the second barrier stack, the substrate and the second barrier stack forming a seal, or between the first barrier stack and the second barrier stack, the first and second barrier stacks forming a seal; and

removing the encapsulated environmentally sensitive device from the rigid support.

2. The method of claim 1 wherein the flexible substrate is temporarily laminated to the rigid support with a reversible adhesive selected from heat activated adhesive, pressure sensitive adhesive, UV activated adhesive, or combinations thereof.

3. The method of claim 1 wherein the flexible substrate is cut into the discrete sheet form before the flexible substrate is laminated adjacent to the rigid support.

4. The method of claim 1 wherein the flexible substrate is cut into the discrete sheet form after the flexible substrate is laminated adjacent to the rigid support.

5. The method of claim 1 wherein the flexible substrate is cut into the discrete sheet form and wherein the first barrier stack is applied before the flexible substrate is cut into the discrete sheet form.

6. The method of claim 1 wherein the flexible substrate is cut into the discrete sheet form and wherein the first barrier stack is applied after the flexible substrate is cut into the discrete sheet form.

7. The method of claim 1 wherein the first barrier stack is applied before the flexible substrate is laminated adjacent to the rigid support.

8. The method of claim 1 wherein the first barrier stack is applied after the flexible substrate is laminated adjacent to the rigid support.

9. The method of claim 1 further comprising separating the encapsulated environmentally sensitive device on the flexible substrate from another encapsulated environmentally sensitive device on the flexible substrate.

10. The method of claim 1 wherein the first barrier stack is applied using a mask.

11. The method of claim 1 wherein the second barrier stack is applied using a mask.

12. The method of claim 1 wherein the first barrier stack is sealed at an edge.

13. The method of claim 1 wherein the second barrier stack is sealed at an edge.

14. The method of claim 1 further comprising applying a functional layer adjacent to the flexible substrate.

15. The method of claim 1 wherein the first barrier stack is applied on a side of the flexible substrate opposite the environmentally sensitive device.

16. The method of claim 1 wherein applying a second barrier stack adjacent to the environmentally sensitive device comprises depositing the second barrier stack adjacent to the environmentally sensitive device.

17. The method of claim 16 wherein depositing the second barrier stack adjacent to the environmentally sensitive device comprises vacuum depositing the second barrier stack adjacent to the environmentally sensitive device.

18. The method of claim 1 wherein applying a second barrier stack adjacent to the environmentally sensitive device comprises laminating the second barrier stack adjacent to the environmentally sensitive device.

19. The method of claim 16 wherein the second barrier stack is laminated adjacent to the environmentally sensitive device using heat, adhesive, or combinations thereof.

20. The method of claim 1 further comprising applying an array of thin film transistors before the environmentally sensitive device is applied.

21. The product produced by the method of claim 1.

22. A method of encapsulating an environmentally sensitive device comprising:

providing a flexible substrate in discrete sheet form;

temporarily laminating the flexible substrate adjacent to a rigid support;

applying a first barrier stack adjacent to the flexible substrate, the first barrier stack comprising at least one barrier layer and at least one decoupling layer;

applying the environmentally sensitive device adjacent to the flexible substrate;

applying a sheet of barrier material adjacent to the environmentally sensitive device to encapsulate the environmentally sensitive device between the first barrier stack and the sheet of barrier material, the first barrier stack and the sheet of barrier material forming a seal; and

removing the encapsulated environmentally sensitive device from the rigid support.