OLED Array Transfer Printing for Layer Thickness Control
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Solution Overview
Problem
Conventional methods for producing organic light emitting diode (OLED) arrays are complex and costly due to the need for vacuum evaporation and high-temperature processes, which complicate the formation of organic light emitting layers.
Innovation Solution
The method involves creating OLED arrays using transfer printing for the hole injection, hole transport, electroluminescent, electron transport, and electron injection layers, while maintaining the electron transport and injection layers through vacuum evaporation to preserve their properties, and forming the layers on convexities arranged in arrays to enhance light emission and visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum evaporation is used to form organic light emitting layers, then the layers can be formed with controlled thickness and properties, but the process becomes complex and costly requiring masks, high temperature, and vacuum devices
Solution Approach 1:
The patent replaces the vacuum evaporation process (mechanical/physical system requiring vacuum devices) with a solution-based coating process. The organic light emitting layer is formed by coating a solution containing organic light emitting materials onto the substrate, eliminating the need for vacuum equipment, masks, and high-temperature processing while maintaining layer formation capability
Solution Approach 2:
The patent changes the state of the organic light emitting material from vapor phase (vacuum evaporation) to solution phase (coating process). This parameter change allows the material to be deposited as a liquid solution that can be easily coated and then dried to form the desired layer, simplifying the overall process
2Manufacturing precision
If vacuum evaporation with masks is used to form organic light emitting layers, then precise patterning can be achieved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent replaces the mask-based vacuum deposition system with a solution coating approach. The organic light emitting layer is formed by coating a solution that can be patterned through the coating process itself or subsequent simple processing, eliminating expensive masks and vacuum equipment while achieving the required patterning
Solution Approach 2:
The patent eliminates the need for expensive, reusable masks by using a direct coating method where the pattern is formed during the coating process or through simple post-processing, replacing costly reusable components with a simpler, more economical process
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 simplifies the production process, reduces costs, and improves the efficiency and visibility of OLED arrays by allowing for flexible layer thickness and arrangement, enabling the creation of monochromatic and full-color displays with enhanced light emission characteristics.
Implementation Method 1
The organic light emitting layer is formed usually by vacuum evaporation which needs mask, high temperature, and vacuum device
Implementation Method 2
an organic electroluminescent material that can luminesce light of a desired color
Data Source
AI summary
The disclosure relates to an organic light emitting diode array. The organic light emitting diode array includes a base defining a number of convexities spaced from each other, a number of first electrodes located on the convexities, a number of electroluminescent layers located on the first electrodes, a patterned second insulative layer located among the convexities to cover part of the base and expose the electroluminescent layers, and a number of second electrodes electrically connected to the electroluminescent layers. The first electrodes are parallel with each other and extend along a first direction. The second electrodes are parallel with each other and extend along a second direction different from the first direction.