Kyoung Woo Parkab,
Seunghee Leea,
Hyunkoo Leec,
Yong-Hwan Chod,
Yong Cheon Parke,
Sung Gap Ime and
Sang-Hee Ko Park*a
aSmart & Soft Materials & Devices Laboratory (SSMD), Department of Materials Science and Engineering, Korea Advanced Institute of Science and Technology (KAIST), 291 Daehak-ro, Yuseong-gu, Daejeon 34141, South Korea. E-mail: shkp@kaist.ac.kr
bModule Development Team, Samsung Display, 1 Samsung-ro, Giheung-gu, Yongin-city, Gyeonggi-do 17113, South Korea
cFlexible Device Research Group, Reality Device Research Division, Electronics and Telecommunications Research Institute (ETRI), 218 Gajeong-ro, Yuseong-gu, Daejeon 34129, South Korea
dDong Woo Fine-Chem, 35, Poseunggongdan-ro 117 Beon-gil, Paseung-eup, Pyeongtaek-si, Gyeonggi-do 17956, South Korea
eFunctional Thin Films Laboratory (FTFL), Department of Chemical and Biomolecular Engineering, Korea Advanced Institute of Science and Technology (KAIST), 291 Daehak-ro, Yuseong-gu, Daejeon 34141, South Korea
First published on 20th December 2018
Highly moisture permeation resistive and transparent single layer thin films for the encapsulation of hydrogenated silicon oxynitrides (H:SiON) were deposited by plasma-enhanced chemical vapor deposition (PECVD) using silane (SiH4), nitrous oxide (N2O), ammonia (NH3), and hydrogen (H2) at 100 °C for applications to a top-emission organic light-emitting diode (TEOLED). Addition of H2 into the PECVD process of SiON film deposition afforded the hydrogenated SiON film, which showed not only improved optical properties such as transmittance and reflectance but also better barrier property to water permeation than PECVD SiON and even SiNx. The H:SiON film with thickness of only 80 nm exhibited water vapor transmission rate (WVTR) lower than 5 × 10−5 g per m2 per day in the test conditions of 38 °C and 100% humidity, where this WVTR is the measurement limit of the MOCON equipment. An additional coating of UV curable polymer enabled the H:SiON films to be flexible and to have very stable barrier property lower than 5 × 10−5 g per m2 per day even after a number of 10k times bending tests at a curvature radius of 1R. The mild H:SiON film process improved the electrical properties of top-emission OLEDs without generating any dark spots. Furthermore, single H:SiON films having high water vapor barrier could maintain the original illumination features of TEOLED longer than 720 hours. These excellent properties of the H:SiON thin films originated from the structural changes of the SiON material by the introduction of hydrogen.
To ensure complete protection of flexible AMOLED displays from water and oxygen, high-performance thin film encapsulation (TFE) with water vapour transmission rate (WVTR) lower than 10−6 g per m2 per day is necessary.7 Moreover, high optical transparency is required because most AMOLEDs used for wearable devices, ultra-high resolution large-area TVs, and transparent displays have top-emission structures. Many studies of TFE on the structure of laminating inorganic and organic layers have been actively carried out because the former and the latter provide excellent barrier properties and flexibility, respectively.8–11 By appropriately laminating the inorganic and organic layers, it is possible to realize excellent TFE that satisfies both requirements of high barrier properties and flexibility.
The laminate structured TFE with inorganic and organic layers, however, has brought about several problems. According to the mechanism for the high barrier properties of the laminated structures, the low permeability of multi-layered structures does not come from the film itself but rather from the interfaces between layers via a delay of water permeability.12 This indicates that an increased number of stacked layers can improve the barrier performance. This complicates the structure of the encapsulation layer with an increase in the thickness of the films. The second problem is the coverage of particles generated during the OLED evaporation process. Only limited materials and deposition methods have been applied to enhance the characteristics of the inorganic barrier layer. Among them, AlOx deposited by the atomic layer deposition (ALD) method is the most representative one for high-performance TFE as it exhibits ultra-thin thickness.13–15 Since the ALD method requires a relatively longer process time than PECVD, AlOx should be relatively much thinner, resulting in poor coverage of particles on OLEDs and degraded encapsulation performance. To solve the above issues, many studies have been attempted to improve the characteristics of the inorganic layer and reduce the number of layers of TFEs.16–18
In this study, by using PECVD at a low temperature of 100 °C or less, we have developed hydrogenated-silicon oxynitride (H:SiON) single layer TFE with high-performance barrier properties. To control the structural characteristics of SiOxNy, a mixture phase of SiOx and SiNxHy was adopted instead of using SiOxNy single phase. The chemical reaction formulas of SiOx, SiNx, and SiOxNy in the PECVD process are shown in (1), (2), and (3).
SiOx:SiH4 + N2O → SiOx + H2 + N2 | (1) |
SiNx:SiH4 + NH3 → SiNx + H2 | (2) |
SiOxNy:SiH4 + N2O + NH3 → SiOxNy + H2 + N2 | (3) |
When hydrogen gas is introduced to the chemical reaction formula (3) with minimized amount of N2O gas, the product can be modified to obtain a new film with hydrogen networks based on SiOxNy. Consequently, high barrier performances can be obtained with a single H:SiON layer.
Furthermore, by coating a single layer of polymer on the H:SiON single layer, we have demonstrated high-performance TFE, which can be applied to OLED and can be used to improve optical characteristics and to ensure good flexibility.
SiON | PECVD deposition conditions | ||||
---|---|---|---|---|---|
Power (W) | Temperature (°C) | Pressure (torr) | Gas ratio (SiH4:N2O:NH3:H2, sccm) | Thickness (nm) | |
Film a | 100 | 100 | 1.5 | 30:30:120:0 | 80 |
Film b | 100 | 100 | 1.5 | 30:30:120:300 | 80 |
Film c | 100 | 100 | 1.5 | 30:30:120:500 | 80 |
Film d | 100 | 100 | 1.5 | 30:30:120:1000 | 80 |
To evaluate the barrier property of the TFE layer on top of the OLED, a top-emitting OLED (TEOLED) was fabricated on glass. The glass substrates were sequentially cleaned with acetone and methanol using an ultrasonic bath, followed by rinsing with deionized water. After drying the substrate, a reflective bottom metal, organic materials and a thin top metal layer were deposited in succession using the vacuum thermal evaporation method without breaking the vacuum. During the deposition of the doping layer, the deposition rates of both the host and dopant materials were controlled with a quartz crystal oscillator. To fabricate reference devices, fabricated devices were transferred to an inert environment glove-box, where they were encapsulated using an UV-curable epoxy and a glass cap containing a moisture getter.
To determine the film density and index value, high resolution X-ray diffractometer (SmartLap, RIGAKU) and ellipsometer (ALPHA-SE, J.A. Woollam) were used. Chemical composition was measured by XPS (K-alpha, Thermo VG Scientific). Data were collected after Ar sputtering for 15 seconds in an ultra-high vacuum (base pressure of under 10−9 torr) to remove impurities on the surface of the sample. Fourier Transform Infrared spectroscopy (FT-IR, HYPERION 3000, Bruker) was also conducted with attenuated total reflectance (ATR) mode to analyze the bonding structure of SiON-based thin films. WVTR was measured to be lower than 5 × 10−5 g per m2 per day (equipment limit at testing sample size of 50 cm2) using Aquatran 2 (MOCON). The water permeability test conditions were 100% in humidity at 38 °C. In addition, optical properties of each sample were examined from 300 nm to 800 nm using UV/VIS/NIR spectrophotometers (SolidSpec-3700, Shimadzu).
The current density–voltage–luminance (J–V–L) characteristics and electroluminescence (EL) spectra of OLEDs were measured using a sourcemeter (Keithley-238, Keithley) and a spectroradiometer (CS-2000, Konica Minolta). All measurements were conducted at room temperature in a dark room. The efficiencies were calculated from the luminance, current density, and EL spectrum.
F. Ay et al.20 reported that reducing the N2O gas amount during the SiOxNy film deposition by PECVD using SiH4, N2O, and NH3 resulted in an SiOxNy film with relatively increased N–H bonding due to the influx of hydrogen from NH3. In fact, the original structure of SiON deposited by PECVD can be described as a random bonding model (RBM) structure with a tetrahedral structure of oxide-rich phase. The latter group suggested that the formation of a nitrogen-rich phase resulted in a random mixing model (RMM) structure with tetrahedral and trigonal structures.21 In our case, however, we added additional H2 gas flow while maintaining minimum amount of N2O flow. H2 seems to promote the formation of Si–N–H bonding, leading to a higher index value due to increased stretching vibration of N–H bonding.19,20 Our SiON thin films with increased Si–N–H networking and decreased Si–O seem to suppress the permeation of water vapor due to the increase in film density along with structural changes even in the same amorphous structure. Therefore, during the PECVD process of SiON films, hydrogen plays an important role in improving the index value and growing H:SiON thin films with dense structures.
According to the results of J. Wu et al.,13 multilayer films with 30 nm-thick Al2O3 deposited using the ALD method and 500 nm-thick polymer layers realized WVTR of less than 10−5 g per m2 per day with a total of 3 dyads (6 layers). Considering the process time of ALD, the total thickness of the multi-layered Al2O3 (90 nm) and polymer with total thickness of 1.5 μm and more complicated multi-layered structure, our barrier film has several advantages over these films. For the single SiNx thin film-based TFE deposited by PECVD, the most recent results were published by H. Nominanda et al.18 The results show that a 500 nm SiNx single layer deposited by the PECVD method exhibits WVTR value of less than 5 × 10−5 g per m2 per day. Considering these recent results, our PECVD processed TFE has advantages in terms of performance and process.
For the potential application of TFE in flexible OLED devices, various evaluations were carried out using film d, which has the best moisture barrier property among various H:SiON films.
Since durability under bending tests is directly related to the lifetime of flexible OLEDs,22,23 it is essential to confirm the mechanical long-term stability of the encapsulation layer. To verify the mechanical properties of film d, we conducted bending tests with various bending radiuses and number of bending times. For the bending test at just 1R bending radius, a 20 μm polyimide substrate was used because 50 μm-thick PET was destroyed in this environment. The barrier property of the single inorganic layer film d was easily degraded after the bending test. To improve the flexibility of this H:SiON film, we coated an acrylate-based polymer on film d by using spin coating, and this was followed by UV curing. Consequently, excellent mechanical reliability was achieved under various bending test conditions, as shown in Fig. 3. Moreover, barrier property lower than 5 × 10−5 g per m2 per day was maintained in the bi-layered structure of film d with an intact polymer layer even after 10k times bending tests at a radius of curvature of 1R, which is a very harsh condition. This indicates that it is applicable to flexible OLED devices.
Improvement of the optical properties results in increased luminescence efficiency of OLEDs; therefore, it is a very important requirement for applications to flexible top-emission OLED displays. One peculiar point in the bi-layered structure coated with a polymer layer on film d is the occurrence of wave fluctuation in the visible range. This phenomenon can be due to interference and scattered reflection of light at the interface by defects such as pin-holes in the polymer layer. To clarify the origin of this fluctuation, we introduced iCVD (initiated chemical vapor deposition) processed polymer with similar thickness and less defects compared to the spin-coated polymer. Since the iCVD method is a vacuum coating process, the particle-related defects can be minimized than spin-coating process.26 As shown in Fig. 5, the wave fluctuation is considerably reduced, indicating that both effects result in wave fluctuation. We assume that there is some interference within the double layered barrier film and now, it is under investigation.
Fig. 5 Optical characteristics of bi-layered TFE with the different coating method of the polymer layer. |
The commercially available flexible AMOLED is typically fabricated on PI of which the coefficient of thermal expansion is less than 7 ppm per °C. Therefore, a substrate barrier film can be deposited at a temperature higher than 300 °C to obtain high barrier property. Here, we focused on OLED thin film encapsulation, which should be deposited under 100 °C. Considering these factors, we fabricated TEOLED on the glass substrate to investigate the electrical and optical characteristics and long-term stability. To compare and evaluate the effect of the encapsulation processes of film d and bi-layered film d with polymer with respect to the TEOLED properties, we measured the electro-optical characteristics of the device such as current density and luminance, as shown in Fig. 6(b) and (c). There were significant differences depending on the addition or non-existence of the polymer layer. The current efficiency values of devices without or with polymer were 45.9 cd A−1 and 56.9 cd A−1, respectively, at 4.2 V. The current efficiency increased by about 16% on average due to the polymer layer. This result, as mentioned above, can be ascribed to the improvement in the optical characteristics of TFE originating from the optical design by Fresnel reflection. As a result, the bi-layered structure coated with a polymer layer on film d not only provides excellent flexibility to TFE but also improves the optical characteristics of TEOLEDs. The operating TEOLED image shown in Fig. 7 also confirms that the TFE process did not induce any kind of damage on the OLED devices.
Fig. 7 Operating images of TEOLEDs (a) without and (b) with a polymer layer, and image (c) after 720 hours shelf lifetime test without the polymer layer. |
We carried out a shelf lifetime test for a TEOLED capped with film d at room temperature for 720 hours. The current densities before and after shelf test at 5.7 V were 1.373 × 10−2 A m−2 and 1.356 × 10−2 A m−2, and the luminance values were 5746 cd m−2 and 5839 cd m−2, respectively, as shown in Fig. 6(b) and (c). No clear change in electrical properties was observed before and after the shelf lifetime test. However, the generation of dark spots can induce an increase in the current density due to the reduction of the active area of the OLED. Therefore, the operating image of the OLED device should be confirmed. Fig. 7(a) and (c) demonstrate operating images of TEOLEDs before and after 720 hour shelf lifetime test. The device encapsulated with film d showed no clear differences or any dark spots after the shelf lifetime test. Therefore, our TFE provides a high level of protection performance for OLED devices without causing any negative effects.
This journal is © The Royal Society of Chemistry 2019 |