OLED Interlayer Uneven Surface for Complete Transfer Layer Separation
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Solution Overview
Problem
In the manufacturing of OLED displays, part of the transfer layer remains on the donor substrate during the laser-induced thermal imaging process, which hinders the complete transfer of the organic emission layer to the display substrate.
Innovation Solution
The method involves forming an interlayer with an uneven surface on the pixel definition layer to increase its surface area, allowing for complete separation of the transfer layer from the donor substrate, and optionally treating the pixel definition layer with plasma to enhance adhesion, ensuring the transfer layer is fully transferred onto the pixel region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser-induced thermal imaging is used to transfer the organic layer, then fine patterning is achieved, but part of the transfer layer remains on the donor substrate
Solution Approach 1:
A separation layer is introduced as an intermediary between the donor substrate and the transfer layer. This separation layer facilitates complete transfer of the transfer layer to the acceptor substrate by preventing adhesion to the donor substrate, thereby resolving the contradiction between achieving fine patterning through LITI and ensuring complete transfer without residual material on the donor substrate
Solution Approach 2:
The surface energy or adhesion properties of the donor substrate or separation layer are modified through parameter changes (such as surface treatment or material selection) to control the transfer behavior. This enables the transfer layer to detach completely from the donor substrate during the LITI process while maintaining fine patterning precision
2Productivity
If the transfer layer is heated for thermal transfer, then the organic layer is transferred to the acceptor substrate, but residual transfer layer remains on the donor substrate
Solution Approach 1:
The separation layer acts as a mediator that enables complete transfer of the transfer layer to the acceptor substrate during thermal processing. By controlling the thermal behavior and adhesion properties of the separation layer, the transfer layer detaches completely from the donor substrate, improving transfer efficiency and eliminating material waste from residual transfer layer
Solution Approach 2:
The thermal transfer process utilizes phase transitions (such as melting or softening) of the transfer layer or separation layer at controlled temperatures. This phase transition enables the transfer layer to flow or detach completely from the donor substrate and adhere to the acceptor substrate, ensuring complete transfer without residual material
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 enables the complete separation and transfer of the transfer layer onto the pixel region, preventing residual transfer layer on the donor substrate and ensuring a successful organic emission layer formation.
Implementation Method 1
the photothermal conversion layer absorbs a laser emitted from the light source and converts the laser into thermal energy
Implementation Method 2
One side of the interlayer has an uneven shape so that the surface area of the interlayer increases
Implementation Method 3
one side of the pixel definition layer is hydrophilic, and the emission layer covers the pixel electrode and the one side of the pixel definition layer
Data Source
AI summary
An organic light-emitting diode (OLED) display according to an exemplary embodiment of 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 definition layer formed on the pixel electrode so as to define a pixel region, an emission layer formed on the pixel electrode and contacting the pixel electrode in the pixel region, and an interlayer formed on the pixel definition layer and contacting part of the emission layer. One side of the interlayer has an uneven shape so that a surface area of the interlayer is increased.