Electronic devices and processes for forming the same

Abstract

An electronic device includes an array. In one embodiment, a process for forming an electronic device includes the array, which includes electronic components, can include printing one or more layers as a series of segments onto a workpiece. In one embodiment, a process includes printing a layer onto the workpiece and at least one exposed portion of the chuck. In still another embodiment, a printing head is greater than 0.5 mm from the workpiece. In a further embodiment, “hybrid” printing can be used to help form a thicker layer having a relatively thinner width. In a further embodiment, processes can be used to reduce the likelihood of a stitching defect, nonuniformity of a layer across an array, or a combination thereof. A printing apparatus can be modified to achieve more flexibility in liquid compositions, temperatures or other conditions used in printing a layer.

Description

RELATED APPLICATION DATA[0001]This application is a division of application Ser. No. 11 / 027,133 filed Dec. 30, 2004.BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]The invention relates generally to electronic devices and processes for forming the same, and more specifically, to electronic devices and processes for printing at least one layer for the electronic devices.[0004]2. Description of the Related Art[0005]Electronic devices, including organic electronic devices, continue to be more extensively used in everyday life. Examples of organic electronic devices include Organic Light-Emitting Diodes (“OLEDs”). A variety of deposition techniques can be used in forming layers used in OLEDs. Techniques for printing layers include ink-jet printing and continuous printing.[0006]Ink-jet printing has been used extensively in the formation of full-color OLED displays due to its ability to dispense precise amounts of liquid. However, ink-jet printers may not be capable of pri...

AI Technical Summary

Benefits of technology

"The patent describes a process for making electronic devices with a layer of organic material. The process involves printing a series of segments onto a workpiece, where each segment is a different liquid composition. The process includes heating the workpiece and continuously printing the liquid compositions onto the workpiece while maintaining the temperature between 5 to 80°C. The resulting device has improved performance and stability. The technical effects of this process include improved device performance and stability."

Problems solved by technology

However, ink-jet printers may not be capable of printing the narrowest of lines.

In addition to having a limited ability to print fine lines, a printing head for an ink-jet printer moves at a rate no greater than approximately 0.1 m / s.

As a result, ink-jet printing is time consuming, leading to limited throughput of devices.

Additionally, ink-jet printers are limited in their ability to print a wide variety of liquid compositions.

At higher concentrations (e.g., viscosities at 15 centipoise and higher), the nozzle for the ink-jet printer has an increased likelihood of clogging or not flowing properly.

At lower solids concentrations, too much volume needs to be dispensed resulting in poor line width control.

For displays in particular, the stitching defects 120 greatly diminish the visual appearance of the display.

In an extreme situation, even the complicated driving scheme may not be able to fully counter the effects of the stitching defects 120.

Images