Organic Light-Emitting Device Patterning via Transfer Substrate
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Solution Overview
Problem
Existing methods for manufacturing organic light-emitting devices using printing techniques face challenges in maintaining light emission efficiency and lifetime, as they often result in deterioration due to impurity entry and contact with blankets during the patterning process.
Innovation Solution
A method involving the formation of a mask on a substrate to selectively remove organic material layers, preventing contact between the blanket and the organic layer, thereby avoiding impurity entry and ensuring precise patterning without the need for pre-forming patterns on a blanket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a reverse offset printing method is used to form patterns on a blanket, then high-definition patterning can be achieved, but impurities from the blanket may enter the organic layer causing deterioration
Solution Approach 1:
The patent introduces a transfer substrate as an intermediary carrier. The organic layer is first formed on this transfer substrate, then transferred to the final substrate. This mediator prevents direct contact between the blanket and the organic layer, eliminating impurity contamination while preserving the high-definition patterning capability of the reverse offset printing method.
2Ease of manufacture
If the blanket directly contacts the organic layer during patterning, then transfer can be achieved, but impurity entry causes deterioration of light emission efficiency and lifetime
Solution Approach 1:
The patent segments the manufacturing process into distinct stages: forming the organic layer on a transfer substrate, then transferring it to the final substrate. This separation allows the blanket to contact only the transfer substrate during patterning, not the organic layer itself, thereby preventing impurity contamination while maintaining transfer capability.
3Ease of manufacture
If traditional printing methods are used, then process cost is reduced, but light emission efficiency and lifetime deteriorate due to impurity entry
Solution Approach 1:
The transfer substrate serves as a mediator that enables traditional low-cost printing methods to be used without compromising device reliability. By isolating the organic layer from direct blanket contact, the method maintains the cost advantages of conventional printing while eliminating the harmful impurity contamination that previously limited device lifetime.
Data Source
AI summary
There is provided a method of manufacturing an organic light-emitting device including: forming a first organic material layer on a substrate; and forming a mask in a first region on the first organic material layer, and then selectively removing the first organic material layer to form a first organic layer in the first region.