Organic Light Emitting Display Laser Transfer Method
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Solution Overview
Problem
The existing methods for manufacturing organic light emitting displays, such as the use of shadow masks and spot beam lasers, face challenges in selective material transfer and material efficiency, leading to increased consumption of organic materials.
Innovation Solution
A method involving the formation of a first electrode and bank layer on a substrate, followed by a medium substrate with an organic layer and absorbing layer, and a mask with openings corresponding to the bank layer, where a line beam laser is used to transfer the organic layer onto the exposed electrode areas, forming an organic light emitting layer, and a second electrode is deposited.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If shadow mask method is used to form organic emitting layer, then material transfer can be achieved, but material use efficiency is low due to hand-down phenomenon and pitch control requirements
Solution Approach 1:
The patent replaces the mechanical shadow mask system with a laser-based transfer system. A laser beam is used to locally heat and transfer organic material from a donor substrate to the target substrate through a photomask, eliminating the mechanical hand-down phenomenon and pitch control issues inherent in shadow mask methods.
Solution Approach 2:
The patent introduces a photomask as an intermediary between the laser source and the organic material. The photomask selectively transmits laser energy to specific areas, enabling precise material transfer without requiring mechanical precision of shadow masks. This intermediary allows decoupling of material consumption from precision requirements.
2Manufacturing precision
If spot beam laser transfer method is used, then selective material transfer can be achieved, but material use efficiency is low as consumed material exceeds transferred material
Solution Approach 1:
The patent forms a complete organic layer on the donor substrate before transfer. This preliminary formation allows the entire organic layer to be prepared in advance, and only the required portions are transferred later, reducing material waste compared to spot-by-spot deposition where material is continuously consumed.
Solution Approach 2:
The patent enables recovery and reuse of the donor substrate after material transfer. The donor substrate, having transferred its organic material, can be cleaned and reused for subsequent transfers, effectively recovering the substrate investment and reducing overall material consumption per unit of transferred material.
3Productivity
If larger panel production is desired, then production scale increases, but process time and material consumption increase with existing methods
Solution Approach 1:
The patent segments the manufacturing process into distinct stages: organic layer formation on donor substrate, mask alignment, laser transfer, and electrode formation. This segmentation allows parallel processing and optimization of each stage independently, enabling larger panel production without proportionally increasing total process time.
Solution Approach 2:
The laser transfer process operates continuously across the panel surface, transferring material in a systematic sweep rather than discrete spot-by-spot operations. This continuous action maintains high productivity while scaling to larger panels, as the laser can cover extensive areas without repeated positioning and setup time.
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 material use efficiency, reduces manufacturing costs, and improves production yield by allowing for larger panel production with reduced process time and improved light emission efficiency.
Implementation Method 1
emitting light on the medium substrate through the mask and transferring the organic layer on a portion of the first electrode exposed by the bank layer to form an organic light emitting layer on the target substrate
Implementation Method 2
emitting light on the medium substrate through the mask and transferring the organic layer
Implementation Method 3
An organic light emitting element used in an organic light emitting display has a self-emission structure in which a light emitting layer is formed between two electrodes on a substrate
Data Source
AI summary
A method of manufacturing an organic light emitting display is disclosed. The method includes forming a first electrode and a bank layer including an opening area exposing the first electrode on a target substrate, forming a medium substrate including an organic layer and an absorbing layer on the target substrate, forming a mask including an opening corresponding to the opening area of the bank layer on the medium substrate, emitting light on the medium substrate through the mask and transferring the organic layer on a portion of the first electrode exposed by the bank layer to form an organic light emitting layer on the target substrate, and forming a second electrode on the organic light emitting layer.