Donor Substrate Photothermal Conversion for Display Patterning
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Solution Overview
Problem
Current methods for patterning organic layers in organic light emitting elements, such as LITI and LIPS, require complex donor substrates with additional photothermal conversion layers, increasing manufacturing costs and light loss due to scattering at interfaces.
Innovation Solution
A simplified donor substrate configuration with a base layer having intrinsic photothermal conversion properties, allowing for efficient transfer of organic materials using a laser with wavelengths between 0.8 μm and 20 μm, directly onto a display substrate, without the need for additional light conversion layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional photothermal conversion layers are added to the donor substrate, then the organic layer can be effectively patterned, but the device complexity and manufacturing cost increase
Solution Approach 1:
The base layer is designed to possess intrinsic photothermal conversion properties, allowing it to self-heat when exposed to laser light without requiring additional photothermal conversion layers. This self-service approach eliminates the need for extra functional layers while maintaining effective patterning capability
Solution Approach 2:
The base layer serves multiple functions simultaneously: it acts as both the structural foundation and the photothermal conversion layer. By combining these functions into a single component, the patent reduces device complexity while maintaining patterning effectiveness
2Manufacturing precision
If additional photothermal conversion layers are added to the donor substrate, then organic layer patterning can be achieved, but light loss due to scattering at interfaces increases
Solution Approach 1:
The patent extracts the photothermal conversion function from separate additional layers and integrates it directly into the base layer. This eliminates unnecessary interface layers that would cause light scattering and energy loss while maintaining the required patterning capability
Solution Approach 2:
The patent creates an asymmetric structure by selecting base layer materials with specific photothermal properties that are not symmetrically equivalent to traditional transparent substrates. This asymmetric material selection optimizes light absorption and conversion while minimizing scattering losses
3Ease of manufacture
If a simplified donor substrate with intrinsic photothermal properties is used, then manufacturing cost is reduced, but the ability to effectively transfer organic material may be compromised
Solution Approach 1:
The patent changes the material parameters of the base layer to possess intrinsic photothermal conversion properties. By selecting materials with appropriate optical absorption coefficients and thermal conversion efficiencies, the base layer can effectively heat and transfer organic material without additional layers, maintaining transfer quality while reducing cost
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
This approach reduces manufacturing costs and minimizes light loss, enabling precise patterning of organic layers while maintaining the integrity of the base layer, thus improving the efficiency and cost-effectiveness of the display device manufacturing process.
Implementation Method 1
a base layer having intrinsic photothermal conversion properties, allowing for efficient transfer of organic materials using a laser with wavelengths between 0.8 μm and 20 μm
Data Source
AI summary
A method for manufacturing a display device includes providing a display substrate including a base substrate having a pixel region and including a first surface and a second surface, which are placed opposite to each other, providing a donor substrate including a base layer and a transfer layer disposed on the base layer and including an organic material such that the transfer layer is spaced apart from the base substrate by a distance, aligning the donor substrate and the display substrate such that the transfer layer faces the first surface of the base substrate, and transferring the transfer layer to the display substrate by irradiating a laser toward the donor substrate on the second surface of the base substrate.