OLED Donor Substrate Transfer Layer Segmentation
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Solution Overview
Problem
In the manufacturing of organic light emitting diode (OLED) displays, the thermal transferring process often results in partial remnants of the transfer layer on the donor substrate, leading to defects in the organic emission layer patterning.
Innovation Solution
The implementation of a donor substrate with a transfer layer that includes an intermediate layer, such as an adhesive or attachable/detachable material, which completely separates the transfer layer from the peripheral region during laser irradiation, ensuring precise transfer of the organic emission layer to the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermal transferring is used to transfer the organic emission layer from the donor substrate, then the organic emission layer can be transferred to the substrate, but partial remnants of the transfer layer remain on the donor substrate leading to defects
Solution Approach 1:
The donor substrate is divided into a transfer region and a peripheral region, with the transfer layer selectively formed only in the transfer region. This segmentation ensures that during laser irradiation, only the transfer layer in the transfer region is transferred to the substrate, while the peripheral region remains intact on the donor substrate, preventing contamination and defects.
Solution Approach 2:
The transfer layer is formed with different properties in different regions: in the transfer region, it has properties that enable complete transfer upon laser irradiation, while in the peripheral region, it maintains properties that prevent unwanted transfer. This local differentiation ensures high transfer completeness in the target area while avoiding defects from peripheral remnants.
2Ease of manufacture
If laser irradiation is used to transfer the organic emission layer, then the transfer process is dry and precisely patterned, but the transfer layer may not be completely separated from the donor substrate
Solution Approach 1:
The transfer layer is pre-formed with specific material properties and structural characteristics that facilitate complete separation upon laser irradiation. The layer is designed in advance to have appropriate thickness, composition, and adhesion characteristics that enable it to be fully transferred when exposed to laser energy, ensuring both dry process capability and transfer completeness.
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 method prevents the partial remnants of the transfer layer on the donor substrate, enhancing the accuracy and completeness of the organic emission layer transfer, thereby improving the manufacturing process and reducing defects.
Implementation Method 1
laser beams output by a light source are absorbed into the light-to-heat conversion layer of the donor film and are then changed into heat energy
Implementation Method 2
an adhesive layer formed on the transfer layer and including an opening of a shape corresponding to the pixel area
Data Source
AI summary
An organic light emitting diode (OLED) display device the present invention includes a substrate, a thin film transistor formed on the substrate, a pixel electrode formed on the thin film transistor and electrically connected to the thin film transistor, a pixel defining layer formed on the pixel electrode and defining a pixel area, an emission layer formed on the pixel electrode and contacting the pixel electrode in the pixel area, and an intermediate layer formed on the pixel defining layer and contacting a portion of the emission layer.