Donor Substrate Metal Layer for Laser Thermal Imaging

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Solution Overview

Problem

Conventional laser-induced thermal imaging methods for organic electroluminescent (EL) display devices face issues with transferring small molecular materials, leading to adhesion problems and staining of the substrate, which deteriorates the luminescence characteristics and efficiency of the display device.

Innovation Solution

A donor substrate is designed with a base film, a light-to-heat conversion layer, a buffer layer, and a transfer layer, where a metal layer or modified layer is included to enhance adhesion and prevent staining, allowing for precise transfer of small molecular organic materials using a laser-induced thermal imaging method.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional donor substrate without a metal layer is used for laser induced thermal imaging, then the structure is simple and manufacturing is easier, but adhesion is poor and substrate staining occurs which deteriorates luminescence characteristics

Engineering Contradiction:

ImproveadhesionVSAvoidstructure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A metal layer is introduced as an intermediary between the buffer layer and the organic material layer. This metal layer serves as a mediator that enhances adhesion between the donor substrate and the organic material, preventing poor adhesion and substrate staining while maintaining reasonable structural complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The donor substrate is constructed as a composite structure comprising a base film, buffer layer, metal layer, and organic material layer. This composite material approach combines the advantages of different materials to achieve both good adhesion and acceptable structural complexity.

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If the laser induced thermal imaging method is used to transfer small molecular organic materials, then transfer precision can be improved, but adhesion problems and substrate staining occur which reduce efficiency

Engineering Contradiction:

Improvetransfer precisionVSAvoidsubstrate staining

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The metal layer acts as an intermediary that prevents direct contact between the organic material and the buffer layer during laser induced thermal imaging. This intermediary layer prevents substrate staining while maintaining the precision of the transfer process.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The metal layer converts the potential harm of direct organic material-substrate contact (which causes staining) into a beneficial adhesion enhancement. The metal layer absorbs the thermal energy during laser irradiation and facilitates controlled transfer while preventing staining.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Manufacturing precision

If a metal layer is added to the donor substrate to improve adhesion, then adhesion and transfer quality improve, but manufacturing complexity increases

Engineering Contradiction:

Improvetransfer qualityVSAvoidmanufacturing

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The metal layer parameters (thickness, material composition) are optimized to achieve the desired adhesion and transfer quality while minimizing the increase in manufacturing complexity. By carefully controlling these parameters, the manufacturing process remains relatively simple.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The improved donor substrate enables efficient and precise transfer of small molecular organic materials, enhancing the voltage-brightness and brightness-efficiency characteristics of organic EL display devices by preventing substrate staining and improving transfer patterns.

Implementation Method 1

a light-to-heat conversion layer formed on the base film

Methodology Applied

Scientific EffectLight-to-heat conversion: Absorption (EM radiation)

Implementation Method 2

light emitted from the light source is absorbed in a light absorption layer of the transfer film and transformed into heat energy

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 3

the heat energy transfers a material for forming a transfer layer from the transfer film to the substrate

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS7517593B2Donor substrate for laser induced thermal imaging method and organic electroluminescent display device fabricated using the same

Publication Date: 2009.04.14 SAMSUNG DISPLAY CO LTD

AI summary

A donor substrate for a laser induced thermal imaging method and an organic electroluminescent display device fabricated using the same are provided. The donor substrate may be constructed with base film; a light-to-heat conversion layer formed on the base film; a buffer layer formed on the entire surface of the light-to-heat conversion layer; a metal layer formed on the buffer layer; and a transfer layer formed of an organic material and formed on the metal layer, thereby enhancing the characteristics of a transfer pattern by transferring a small molecular material using the laser induced thermal imaging method.