OLED Array Fabrication via Transfer Printing and Convex Base
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Solution Overview
Problem
Conventional methods for manufacturing 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 organic light emitting layers.
Innovation Solution
The method involves creating OLED arrays with a base having convexities, where organic light emitting diodes are formed using transfer printing for layers such as the hole injection, hole transport, and electroluminescent layers, while electron transport and injection layers are made by vacuum evaporation, allowing for a more efficient and 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 requiring mask, high temperature, and vacuum device
Solution Approach 1:
The patent extracts the organic light emitting layer formation process from the vacuum evaporation method and replaces it with a solution-based coating method. This removes the need for vacuum devices, masks, and high-temperature processing, thereby reducing device complexity while maintaining layer quality through controlled solution deposition and drying processes
Solution Approach 2:
The patent substitutes the mechanical vacuum evaporation system with a chemical solution-based system. Instead of using vacuum equipment and thermal evaporation mechanisms, the organic light emitting layer is formed by applying organic precursor solutions that decompose and form the desired layer structure through chemical reactions during low-temperature processing
2Manufacturing precision
If vacuum evaporation method is used to form organic light emitting layer, then the control over layer thickness and composition is improved, but the loss of time and energy increases due to high temperature and vacuum requirements
Solution Approach 1:
The patent changes the processing parameters from high-temperature vacuum evaporation to low-temperature solution processing. By using soluble organic precursors and controlling the drying and decomposition conditions, the method achieves precise control over layer thickness and composition without requiring energy-intensive high-temperature and vacuum conditions, thereby reducing processing time and energy loss
3Manufacturing precision
If conventional vacuum evaporation method is used, then the organic light emitting layer can be formed with good quality, but the manufacturing cost increases due to high equipment and operational requirements
Solution Approach 1:
The patent employs inexpensive organic precursor solutions that can be applied using simple coating techniques. The organic precursors are deposited as solutions and then thermally decomposed to form the organic light emitting layer, eliminating the need for expensive vacuum deposition equipment and reducing manufacturing costs while maintaining layer quality
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 simplifies the production of OLED arrays by reducing the reliance on vacuum evaporation and high-temperature processes, making the method more efficient and cost-effective while maintaining the quality of the organic light emitting layers.
Implementation Method 1
heating the first template so that the organic electroluminescent film is decomposed
Implementation Method 2
The organic light emitting layer is formed usually by vacuum evaporation
Data Source
AI summary
The disclosure relates to a method of making organic light emitting diode array. A base defining a number of convexities is provided. Three of the convexities, that correspond to the same pixel unit, have different heights. A number of first electrodes are applied on the number of convexities. A number of electroluminescent layers are transfer printed on the number of first electrodes to form the number of organic light emitting layers. A patterned second insulative layer is made to cover the number of first electrodes and expose the number of organic light emitting layers. A second electrode is electrically connected to the number of organic light emitting layers.