OLED Array Transfer Printing and Convex Substrate Design
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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 transfer printing for the hole injection, hole transport, electroluminescent, electron transport, and electron injection layers, while maintaining the electron transport and injection layers through vacuum evaporation to preserve their properties, and forming the OLEDs on a substrate with convexities to enhance light emission and adjust the angle of emergent light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum evaporation is used to form the organic light emitting layer, then the layer can be deposited with good quality, but the process becomes complex and costly requiring masks, high temperature, and vacuum devices
Solution Approach 1:
The patent segments the organic light emitting layer into multiple sub-layers (hole injection layer, hole transport layer, electroluminescent layer, electron transport layer, electron injection layer), each formed by different methods. This allows each sub-layer to be optimized independently, with transfer printing used for most layers to simplify the process while maintaining quality.
Solution Approach 2:
The patent introduces a template as an intermediary carrier to form the organic light emitting layers before transferring them to the substrate. This intermediary approach enables precise layer formation without requiring complex in-situ vacuum deposition processes on the final substrate, thereby reducing device complexity.
2Manufacturing precision
If vacuum evaporation is used to form the organic light emitting layer, then the layer can be deposited with good quality, but the production cost increases due to required equipment
Solution Approach 1:
The patent uses a disposable template that can be discarded after transferring the organic light emitting layers to the substrate. This eliminates the need for expensive vacuum deposition equipment and masks, significantly reducing production cost while maintaining layer quality through the template-based transfer printing method.
3Manufacturing precision
If conventional vacuum evaporation method is used, then the organic light emitting layer can be formed, but the production time increases due to complex process steps
Solution Approach 1:
The patent performs preliminary formation of the organic light emitting layers on a separate template before transferring them to the substrate. This preliminary action allows for simplified, faster layer formation without the constraints of in-situ vacuum processing, thereby improving production efficiency 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 process, reduces costs, and allows for the creation of efficient OLED arrays with improved light emission characteristics by using transfer printing for key layers and maintaining critical layers through vacuum evaporation, enabling flexible and cost-effective production of OLED arrays.
Implementation Method 1
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 plurality of convexities is provided. A number of first electrodes are applied on the plurality of convexities. A number of red light electroluminescent layers are transfer printed on a first group of the first electrodes. A number of green light electroluminescent layers are transfer printed on a second group of the first electrodes. A number of blue light electroluminescent layers are transfer printed on a third group of the first electrodes. A patterned second insulative layer is made to cover the number of first electrodes and expose the electroluminescent layers. A second electrode is electrically connected to the electroluminescent layers.