OLED Array Fabrication via Nanoimprinting
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Solution Overview
Problem
Conventional methods for manufacturing organic light emitting diodes (OLEDs) are complex and costly due to the need for vacuum evaporation and high-temperature processes, which complicate the formation of the organic light emitting layer.
Innovation Solution
A nanoimprinting method is employed, where a template with a patterned surface is used to form a patterned organic layer, allowing for the deposition of an organic light emitting layer without the need for masks, using a process that can be conducted at room temperature and in a vacuum environment, resulting in protruding structures on the organic layer for improved luminescence and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum evaporation method is used to form organic light emitting layer, then deposition precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces the complex vacuum evaporation mechanical system with a simple spin coating process. The organic light emitting layer is formed by spinning a solution containing organic light emitting material onto the substrate, eliminating the need for vacuum equipment, masks, and high-temperature processes while achieving sufficient deposition precision for OLED fabrication
Solution Approach 2:
The patent changes the deposition parameters from vacuum evaporation conditions to ambient temperature spin coating conditions. By dissolving organic light emitting material in a solvent and applying it as a solution, the process can be conducted at room temperature without vacuum equipment, significantly simplifying the manufacturing system while maintaining layer quality
2Manufacturing precision
If vacuum evaporation method is used to form organic light emitting layer, then deposition precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive vacuum evaporation equipment with simple spin coating equipment. The organic light emitting layer is deposited by spinning a material solution onto the substrate, eliminating the need for costly vacuum chambers, masks, and high-temperature furnaces, thereby dramatically reducing manufacturing cost while achieving acceptable deposition precision
Solution Approach 2:
The patent uses a solution-based approach where organic light emitting material is dissolved in a solvent and applied as a disposable coating. This eliminates the need for expensive reusable vacuum equipment and masks, reducing overall manufacturing cost even though the material solution is consumed in the process
3Reliability
If conventional method with masks and high temperature is used, then organic light emitting layer is formed, but process complexity increases
Solution Approach 1:
The patent replaces the complex multi-step process involving masks, vacuum evaporation, and high-temperature processing with a single spin coating step. The organic light emitting material is applied as a solution and cured at low temperature, eliminating the need for masks and high-temperature equipment while maintaining reliable layer formation
Solution Approach 2:
The patent performs preliminary preparation by dissolving the organic light emitting material in a suitable solvent before application. This pre-prepared solution can be directly coated onto the substrate without requiring masks or high-temperature processing during deposition, simplifying the overall process while ensuring reliable layer formation through controlled solution composition
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 simplifies the production process, enhances the luminescence effect, extends the lifespan of OLEDs, and achieves high resolution, making it suitable for roll-to-roll processing and reducing costs while maintaining high pixel density.
Implementation Method 1
A nanoimprinting method is employed, where a template with a patterned surface is used to form a patterned organic layer
Implementation Method 2
depositing an organic light emitting layer on the second patterned surface
Data Source
AI summary
A method of making organic light emitting diode array includes following steps. A base having a number of first electrodes on a surface of the base is provided. A first organic layer is located on the surface of the base to cover the first electrodes. A template with a first patterned surface is provided, wherein the first patterned surface includes a number of grooves with different depths. The first patterned surface of the template is attached on the first organic layer and separated from each other, wherein a number of protruding structures with different heights is formed. An organic light emitting layer is deposited to cover the protruding structures. A second organic layer is located on the organic light emitting layer. A second electrode is applied to electrically connected to the second organic layer.