Organic EL Transfer Plate Pressure Gradient Fabrication
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Solution Overview
Problem
Existing methods for fabricating organic electroluminescent display devices are unsuitable for large-area applications due to alignment errors, material limitations, and difficulty in applying uniform pressure, making them unreliable for manufacturing high-resolution, large-area displays.
Innovation Solution
A method involving a transfer plate with patterns is used, where a substrate is bonded to the transfer plate and organic light emitting patterns are transferred onto the substrate using a pressure difference between the active and outside regions, ensuring uniform pressure and adhesion for large-area device manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shadow mask method is used for forming RGB emitting layers, then alignment can be achieved, but alignment errors occur and high resolution is difficult to obtain for large-area display devices
Solution Approach 1:
The patent introduces a transfer plate as an intermediary carrier that holds the organic emitting layer patterns. The transfer plate mediates the transfer process from a master pattern to the substrate, eliminating direct alignment requirements between mask and substrate. This intermediary approach ensures high precision and reliability for large-area displays.
2Adaptability or versatility
If inkjet method is used for forming organic emitting layers, then polymer materials can be deposited, but the method is mainly limited to polymer applications and lacks versatility
Solution Approach 1:
The patent uses a master pattern on the transfer plate that is copied onto the substrate through the transfer process. This copying mechanism allows precise pattern formation regardless of the organic material type, providing both precision and versatility for different materials including small molecules and polymers.
3Manufacturing precision
If LITI method is used for transferring RGB emitting layers, then pattern transfer can be achieved, but an additional polymer film is required and the process becomes difficult to perform
Solution Approach 1:
The patent extracts and eliminates the unnecessary polymer film step from the LITI process. The organic emitting layer is directly formed and transferred on the transfer plate without requiring an additional polymer carrier film, simplifying the process while maintaining high pattern transfer precision.
4Manufacturing precision
If micropatterning method is used for removing undesired portions, then pattern definition can be achieved, but peripheral portions are not kept clean and uniform pressure is difficult to apply for large-area devices
Solution Approach 1:
Instead of removing undesired portions from the emitting layer (subtractive approach), the patent inverts the approach by directly forming the emitting layer only in the desired pattern areas on the transfer plate. This additive approach ensures clean peripheral portions and enables uniform pressure application across large areas during the transfer process.
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 enables the reliable fabrication of organic electroluminescent display devices with uniform characteristics across the entire substrate, suitable for large-area applications by ensuring uniform pressure and improved adhesion of organic light emitting patterns.
Implementation Method 1
transferred by applying a pressure difference between an active area within the region and an area outside of the region
Data Source
AI summary
A method for fabricating an organic electroluminescent display device usable for large-area applications includes: preparing a first substrate; preparing a transfer plate having at least one transfer pattern; forming a first electrode on the first substrate; forming organic light emitting patterns on the at least one transfer pattern on the transfer plate within a region; and bonding the first substrate to the transfer plate, and after the bonding, transferring the organic light emitting patterns from the transfer plate onto the first substrate using a pressure difference between an area within the region and an area outside of the region.