Donor Substrate Selective Heat Generation for OLED Transfer
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Solution Overview
Problem
The existing laser thermal transfer imaging method for organic light emitting displays requires highly accurate and costly laser apparatuses to form minute transfer layer patterns, increasing fabrication costs.
Innovation Solution
A donor substrate with a selective heat generation structure, including a base substrate and a light-to-heat conversion layer pattern, allows for the formation of minute transfer layer patterns without precise control of the laser beam width by using a reflective layer to enhance light-to-heat conversion and a heat non-generation region to control heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a laser beam with accurately controlled width is used to form minute transfer layer patterns, then the manufacturing precision is improved, but the device complexity and fabrication cost increase due to requiring highly accurate laser apparatus
Solution Approach 1:
The patent introduces a light-to-heat conversion layer as an intermediary between the laser beam and the transfer layer. This layer converts the laser energy to heat, which then transfers to the transfer layer to enable pattern formation. The intermediary layer allows the use of less precise laser beams while still achieving accurate pattern transfer through thermal diffusion control.
Solution Approach 2:
The patent changes the parameter from direct laser beam width control to light-to-heat conversion layer properties control. By adjusting the absorption coefficient, thickness, and thermal properties of the conversion layer, the heat distribution can be precisely controlled even with a broader laser beam, thereby achieving accurate pattern formation without requiring highly accurate laser apparatus.
2Manufacturing precision
If a laser beam with accurately controlled width is used to form minute transfer layer patterns, then the manufacturing precision is improved, but the fabrication cost increases
Solution Approach 1:
The light-to-heat conversion layer serves as a mediator that decouples the relationship between laser beam precision and pattern formation accuracy. This intermediary enables the use of cost-effective, less precise laser equipment while maintaining high manufacturing precision through the thermal diffusion characteristics of the conversion layer.
Solution Approach 2:
The patent employs a consumable light-to-heat conversion layer that can be easily fabricated and replaced. This layer acts as a disposable element that absorbs the precision requirements, allowing the use of cheaper laser equipment. The conversion layer itself becomes the precision-critical component rather than the expensive laser apparatus.
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
Enables accurate and cost-effective formation of minute transfer layer patterns in organic light emitting displays, reducing the need for expensive high-accuracy laser equipment.
Implementation Method 1
the light-to-heat conversion layer in the areas onto which the laser beam is irradiated absorbs the laser beam, and converts the laser beam to thermal energy
Implementation Method 2
A donor substrate includes a base substrate and a light-to-heat conversion layer pattern selectively disposed on a part of the base substrate
Data Source
AI summary
A donor substrate for use in an organic light emitting display comprises a base substrate and a transfer layer disposed on the base substrate. A selective heat generation structure is interposed between the base substrate and the transfer layer. The selective heat generation structure has a heat generation region from which heat is generated by light-to-heat conversion and a heat non-generation region contacting the heat generation region. By employing the donor substrate, it is possible to form minute transfer layer patterns with high accuracy without the need to accurately control the width of a laser beam. A fabrication method of an organic light emitting display comprises disposing the donor substrate on an acceptor substrate, irradiating a laser beam onto the donor substrate, and forming a transfer layer pattern on a pixel electrode of the acceptor substrate.