Donor Substrate Recesses for Laser Transfer of OLED Layers
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Solution Overview
Problem
Existing organic light emitting display devices face contamination and color mixing issues due to static electricity during the transfer of organic transfer layers, which affects the formation of precise micro-sized organic light emitting layers.
Innovation Solution
A donor substrate with recess structures and light-to-heat conversion layers is used, featuring an organic transfer layer on the light-to-heat conversion layer, where the substrate includes a transparent material and isolation structures to prevent mixing, allowing for effective laser-induced thermal imaging and precise transfer of micro-sized organic layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If organic transfer layers are transferred using a laser beam, then organic light emitting layers can be formed on pixel electrodes, but contaminations are frequently generated due to static electricity and color mixing of adjacent pixels occurs
Solution Approach 1:
The patent divides the transfer process into separate color channels by forming red, green, and blue organic transfer layers on separate donor substrates. Each donor substrate is processed and transferred independently, preventing color mixing between adjacent pixels and reducing contamination from static electricity accumulation during a single prolonged transfer operation.
Solution Approach 2:
The patent introduces a donor substrate as an intermediary carrier that holds the organic transfer layers before transfer. This intermediary structure allows for controlled laser-induced thermal imaging transfer, reducing direct contact and static electricity generation between the organic layers and the pixel electrode, thereby minimizing contamination.
2Manufacturing precision
If organic transfer layers are made micro-sized for precise pixel formation, then color mixing is reduced, but transfer precision and alignment become more difficult
Solution Approach 1:
The patent performs preliminary patterning of the organic transfer layers on the donor substrate before the actual transfer to the pixel electrode. The red, green, and blue organic layers are pre-formed in their final micro-sized configurations on the donor substrate, ensuring precise alignment marks and positioning are established beforehand, which facilitates accurate transfer without color mixing.
3Productivity
If donor substrates are reused multiple times, then manufacturing cost is reduced, but contamination accumulates and transfer quality deteriorates
Solution Approach 1:
The patent extracts the organic transfer layers from the donor substrate through laser-induced thermal imaging transfer, completely removing the organic material from the donor substrate. This extraction process allows the donor substrate to be reused multiple times without contamination accumulation, as the organic layers are fully transferred to the pixel electrodes, maintaining consistent transfer quality across multiple reuse cycles.
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 solution enables the effective and reusable transfer of micro-sized organic transfer layers, reducing contamination and color mixing, and allowing for precise formation of organic light emitting layers with improved mechanical strength and recyclability of the donor substrate.
Implementation Method 1
a light-to-heat conversion layer (130) and an organic transfer layer (140). The substrate (110) may have a recess (115) and an isolation structure (117) adjacent to the recess (115). The light-to-heat conversion layer (130) may be disposed in the recess (115)
Implementation Method 2
the organic transfer layers may be transferred onto the pixel electrode using a laser beam, thereby forming the organic light emitting layers on pixel electrodes
Data Source
AI summary
A donor substrate having a plurality of recesses and isolation structures may be provided. The isolation structures may be defined by the recesses. A first electrode is formed on a first substrate. A pixel defining layer may be formed on the first electrode to define a plurality of pixel regions. The donor substrate may be arranged over the first substrate, and a laser induced thermal imaging process may be performed to form a plurality of light emitting layers in the pixel regions. A second electrode may be formed on the pixel defining layer and the light emitting layers. The organic light emitting layers having minute dimensions may be effectively obtained from the donor substrate. The isolation structures may be formed integrally with the substrate, and thus the donor substrate may be easily recycled after the laser induced thermal imaging process.