Electronic device with reduced non-device edge area
A first product may be provided that comprises a substrate having a first surface, a first side, and a first edge where the first surface meets the first side; and a device disposed over the substrate, the device having a second side, where at least a first portion of the second side is disposed within 3 mm from the first edge of the substrate. The first product may further comprise a first barrier film that covers at least a portion of the first edge of the substrate, at least a portion of the first side of the substrate, and at least the first portion of the second side of the device.
1. A method comprising:
obtaining a flexible substrate having a first surface;
creating a notch on the first surface of the flexible substrate to create a first wall of the notch and a first edge where the first wall meets the first surface;
after creating the notch, disposing a plurality of organic light emitting diodes (OLEDs) over the first surface of the flexible substrate such that a first OLED of the plurality of OLEDs is separated from a second OLED of the plurality of OLEDs by the notch, wherein at least the first OLED has a second side and at least a first portion of the second side is disposed not more than 1.0 mm from the first edge;
after providing the flexible substrate, depositing a first barrier film so as to cover at least a portion of the first edge, at least a portion of the first wall of the notch, and a portion of each OLED of the plurality of OLEDs other than those in contact with the first surface of the flexible substrate; and
after the first barrier film is deposited, breaking the flexible substrate along the notch such that the first barrier film continues to cover the portions of the OLED other than those in contact with the first surface of the flexible substrate, including the portions of the first edge of the flexible substrate, so that the first barrier film is only in physical contact with the OLED and a portion of the flexible substrate.
2. The method of claim 1 , wherein the notch has vertical walls relative to the first surface of the flexible substrate.
3. The method of claim 1 , wherein the notch has walls forming an obtuse angle with the first surface of the flexible substrate.
4. The method of claim 1 , wherein the first barrier film is a hybrid layer comprising a mixture of polymeric material and non-polymeric material, and the hybrid layer has a wetting contact angle in a range of 30° to 60°.
5. The method of claim 4 , wherein the polymeric material includes organosilicon polymers selected from a group consisting of a polysiloxane, polycarbosilane, and polysilane, and the non-polymeric material includes silicon oxides or silicon nitrides.
6. The method of claim 1 , wherein the flexible substrate is selected from metal foils or plastics.