Donor Substrate Rib Structure for Damage-Free Organic Layer Transfer

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Solution Overview

Problem

Conventional laser induced thermal imaging processes for forming organic layers in organic light emitting display devices often result in pixel failure due to damage of the organic layer pattern when the donor substrate is removed from the display substrate.

Innovation Solution

A donor substrate with a rib structure, comprising a base substrate, a light-to-heat conversion layer, a transfer layer, and a rib structure featuring tubes with openings and connection tubes, allows for the easy removal of the donor substrate without damaging the organic layer pattern by releasing gases through the rib structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a conventional laser induced thermal imaging process is used to form organic layers, then the organic layer pattern can be transferred onto the display substrate, but the organic layer pattern may be damaged when the donor substrate is removed, causing pixel failure

Engineering Contradiction:

Improveintegrity of organic layer patternVSAvoidpixel failure

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The invention introduces a rib structure with multiple tubes that divide the donor substrate into separable regions. This segmentation allows controlled separation between the donor substrate and display substrate during removal, preventing damage to the organic layer pattern while enabling complete transfer.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The rib structure acts as an intermediary mechanism between the donor substrate and display substrate. It facilitates controlled interaction and separation, mediating the removal process to prevent direct damage to the organic layer pattern while ensuring reliable pixel formation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the donor substrate is removed after transfer to complete the manufacturing process, then the display substrate can be finalized, but the organic layer pattern may be torn off causing pixel failure

Engineering Contradiction:

Improvecompletion of manufacturing processVSAvoidpixel failure

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The rib structure segments the donor substrate into manageable sections through multiple tubes, allowing systematic removal without compromising the integrity of the transferred organic layer pattern. This enables complete manufacturing process completion while maintaining pixel reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The rib structure is pre-formed on the donor substrate before the transfer process. This preliminary structural preparation ensures that the controlled separation mechanism is already in place, enabling damage-free removal and preventing pixel failure during the final manufacturing steps.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If a rib structure with tubes is introduced to enable safe removal, then pixel failure is prevented, but the device complexity increases

Engineering Contradiction:

Improvepixel failure preventionVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

While the rib structure does increase complexity, the segmentation into multiple tubes provides a systematic and scalable solution. The modular tube design allows the complexity to be managed through repetition of standardized components rather than requiring complex custom mechanisms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The rib structure with tubes creates a porous-like configuration that enables gas or fluid passage for controlled separation. This approach uses a relatively simple geometric feature (tubes) rather than complex mechanical systems, balancing reliability improvement with acceptable device complexity.

Inventive Principle:

Principle #31Porous materials

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

Prevents or reduces pixel failure by enabling the safe removal of the donor substrate, ensuring the integrity of the organic layer pattern on the display substrate.

Implementation Method 1

a light-to-heat conversion layer, a transfer layer, and a rib structure. The light-to-heat conversion layer may be on the base substrate. The transfer layer may be on the light-to-heat conversion layer

Methodology Applied

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

Implementation Method 2

The rib structure may include a plurality of tubes spaced apart from one another. The tubes may include a plurality of openings at at least one of upper portions or side portions of the tubes

Methodology Applied

Scientific EffectGas release through porous structure: Porosity

Data Source

PatentUS8727826B2Donor substrate, method of manufacturing a donor substrate and a method of manufacturing an organic light emitting display device using a donor substrate

Publication Date: 2014.05.20 SAMSUNG DISPLAY CO LTD

AI summary

A donor substrate may include a base substrate, a light-to-heat conversion layer, a transfer layer, and a rib structure. The light-to-heat conversion layer may be on the base substrate. The transfer layer may be on the light-to-heat conversion layer. The rib structure is on the transfer layer. The rib structure may include a plurality of tubes spaced apart from one another. In a laser induced thermal imaging process, the donor substrate including the rib structure may be easily removed from a display substrate without damage, thereby to form an organic layer pattern regularly on the display substrate.