OLED Array Transfer Printing via Convex Substrate
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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 the organic light emitting layer.
Innovation Solution
The method involves creating OLED arrays using a base with convexities, where the organic light emitting diodes are formed by transfer printing of layers such as the hole injection layer, hole transport layer, and electroluminescent layer, with optional electron transport and injection layers, allowing for a simpler and potentially more cost-effective production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum evaporation method is used to form organic light emitting layer, then the quality and uniformity of organic light emitting layer is improved, but the device complexity and manufacturing cost increase due to need for vacuum equipment and masks
Solution Approach 1:
The patent replaces the vacuum evaporation mechanical system with a solution-based coating system. Organic light emitting layers are formed by coating solutions onto the substrate, eliminating the need for vacuum equipment and masks. This substitution maintains layer quality while dramatically simplifying the manufacturing process and reducing equipment complexity.
Solution Approach 2:
The patent changes the physical state parameter of organic materials from vapor phase (vacuum evaporation) to solution phase (coating). By dissolving organic compounds in solvents and applying them as solutions, the process avoids vacuum requirements while achieving uniform layer formation through controlled drying and solvent evaporation.
2Manufacturing precision
If conventional vacuum evaporation method is used, then precise control of organic light emitting layer thickness is achieved, but the manufacturing cost and process complexity increase
Solution Approach 1:
The patent controls layer thickness by adjusting solution concentration, coating speed, and drying conditions rather than using vacuum deposition rate control. This approach achieves precise thickness control through solution parameters that are easier and cheaper to manipulate, reducing manufacturing complexity and cost.
Solution Approach 2:
The patent replaces the mechanical vacuum deposition control system with a solution-based coating control system. Thickness is controlled by solution properties and coating process parameters rather than vacuum pump speed and deposition time, simplifying the manufacturing process while maintaining precision.
3Reliability
If high temperature processes are used in OLED fabrication, then the crystallinity and performance of organic layers are improved, but the energy consumption and risk of substrate damage increase
Solution Approach 1:
The patent changes the thermal processing parameters by using solution-based methods that require lower temperatures. Organic layers are formed at or near room temperature through solution coating and controlled drying, eliminating the need for high-temperature vacuum evaporation while maintaining layer quality and reducing energy consumption.
Solution Approach 2:
The patent replaces thermal energy input from high-temperature vacuum evaporation with chemical energy from solution coating and controlled solvent evaporation. This substitution achieves organic layer formation at lower temperatures, reducing energy consumption and substrate damage risk while maintaining layer performance.
Data Source
AI summary
The disclosure relates to a method of making organic light emitting diode array. A base defining a plurality of convexities is provided. A number of first electrodes are applied on the plurality of convexities. A patterned second insulative layer is made among the convexities to cover first parts of the first electrodes between the convexities and expose second parts of the first electrodes on top surfaces of the convexities to form a number of protrudent portions. A number of electroluminescent layers are transfer printed on the number of protrudent portions to form a number of organic light emitting layers. A second electrode is electrically connected to the number of organic light emitting layers.