Nucleation-Inhibiting Coating for OLED Patterning

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for patterning and deposition in OLED manufacturing are limited by high evaporation temperatures, accuracy issues, and debris creation, which increase costs and complexity, and are not suitable for all topographical features.

Innovation Solution

A layered device with a nucleation-inhibiting coating (NIC) containing a rare earth element is used, where the NIC has a low initial sticking probability for deposition, allowing selective deposition of a closed coating in a second portion, while being devoid of the coating in the first portion, enabling precise patterning without the need for fine metal masks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a fine metal mask (FMM) is used during deposition, then selective deposition can be achieved, but the high evaporation temperatures reduce mask reusability and pattern accuracy

Engineering Contradiction:

Improvepattern accuracyVSAvoidmask reusability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent extracts the patterning function from the metal mask and transfers it to the deposited material itself. By controlling nucleation and growth conditions, the material self-organizes into the desired pattern, eliminating the need for a physical mask and its associated temperature and reusability problems.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical metal mask system is replaced with a chemical/physical field-based approach. Instead of using a physical barrier to define patterns, the invention uses controlled deposition fields and nucleation mechanisms to achieve selective material placement without mechanical masks.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If laser drilling is used to remove unwanted regions, then patterns can be formed, but debris is created that affects manufacturing yield

Engineering Contradiction:

Improvepattern formationVSAvoiddebris

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent performs preliminary patterning during the deposition process itself by controlling where nucleation occurs and how growth proceeds. This prevents the need for subsequent removal operations, as the unwanted regions never form in the first place, avoiding debris generation entirely.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention converts the typically harmful effect of uncontrolled nucleation into a beneficial self-organizing mechanism. By understanding and controlling nucleation kinetics, the material naturally forms the desired pattern, turning what could be a source of defects into a patterning tool.

Inventive Principle:

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

3Productivity

If conventional deposition methods are used, then material can be deposited, but selective deposition is difficult to achieve without masks

Engineering Contradiction:

Improvedeposition efficiencyVSAvoidselective deposition

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating different nucleation conditions in different regions of the substrate. By varying surface properties, temperature gradients, or deposition parameters locally, selective deposition occurs in specific areas while other areas remain unaffected, achieving both efficiency and precision.

Inventive Principle:

Principle #3Local quality

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 enhances the precision and efficiency of patterning and deposition, reducing costs and complexity, and is suitable for various topographical features, improving the manufacturing process of OLEDs.

Implementation Method 1

a nucleation-inhibiting coating (NIC) containing a rare earth element is used, where the NIC has a low initial sticking probability for deposition

Methodology Applied

Scientific EffectNucleation inhibition: Nucleation

Implementation Method 2

the NIC has a low initial sticking probability for deposition, allowing selective deposition of a closed coating in a second portion

Methodology Applied

Scientific EffectSticking probability: Adsorption

Data Source

PatentUS20230354677A1Nucleation-inhibiting coating containing rare earth compounds and devices incorporating same

Publication Date: 2023.11.02 OTI LUMIONICS INC

AI summary

A device having a plurality of layers comprises a nucleation-inhibiting coating (NIC) disposed on a first layer surface in a first portion of a lateral aspect thereof; and a deposited layer comprised of a deposited material, disposed on a second layer surface, wherein an initial sticking probability against deposition of the deposited layer onto a surface of the NIC in the first portion is substantially less than the initial sticking probability against deposition of the deposited layer onto the second layer surface, such that the NIC is substantially devoid of a closed coating of the deposited material and wherein the NIC comprises a compound containing a rare earth element. The deposited layer can comprise a closed coating on the second layer surface in a second portion of the lateral aspect, and/or a discontinuous layer of at least one particle structure on a surface of the NIC.