OVJP Injection Block With Flexible Bellows for Precise OLED Deposition

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Solution Overview

Problem

Existing OLED fabrication methods face challenges in achieving precise and efficient deposition of organic materials on flexible substrates, particularly in large-scale production, due to the limitations of fine metal masks and solvent-based inkjet printing, which degrade performance.

Innovation Solution

The use of organic vapor jet printing (OVJP) with a flexible bellows and a monolithic injection block that allows for precise deposition of organic materials on flexible substrates, maintaining temperature stability and enabling vertical movement relative to the substrate, eliminating the need for fine metal masks and solvents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If fine metal masks are used for OLED fabrication, then deposition precision is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvedeposition precisionVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent removes the fine metal mask component from the deposition system entirely, replacing it with a maskless organic vapor jet printing approach that uses direct digital patterning to achieve precise material deposition without physical masks

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical mask system is replaced with a digital control system that directs organic vapor deposition through programmed jetting, substituting physical mechanical components with electronic control and software-based patterning

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If solvent-based inkjet printing is used, then ease of manufacture is improved, but material purity and device performance deteriorate due to solvent residues

Engineering Contradiction:

Improveease of manufactureVSAvoiddevice performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the fundamental parameter of the deposition process from solution-based to vapor-based, eliminating the solvent component entirely while maintaining the inkjet printing delivery mechanism, thus achieving both ease of manufacture and high material purity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the potential harm of solvent residues into a benefit by completely eliminating solvents from the process, using pure organic vapor that deposits cleanly without any liquid carrier or chemical contaminants

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Stability of the object's composition

If rigid injection blocks are used, then structural stability is improved, but adaptability to flexible substrates and thermal management deteriorate

Engineering Contradiction:

Improvestructural stabilityVSAvoidsubstrate compatibility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent replaces rigid injection block structures with flexible bellows components that can expand and contract, allowing the system to adapt to flexible substrates while maintaining structural integrity and enabling thermal expansion without damage

Inventive Principle:

Principle #30Flexible shells and thin films

4Ease of operation

If temperature variations occur during deposition, then ease of operation is improved, but deposition precision and material quality deteriorate

Engineering Contradiction:

Improveease of operationVSAvoiddeposition precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent implements active thermal management systems with temperature sensors and control mechanisms that continuously monitor and adjust heating elements, creating a feedback loop that maintains precise temperature control throughout the deposition process

Inventive Principle:

Principle #23Feedback

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

OVJP enables high-precision, solvent-free deposition of organic materials, enhancing the performance and scalability of OLED production by maintaining temperature stability and allowing for flexible substrate compatibility.

Implementation Method 1

A flexible bellows may be disposed within the internal recess within the injection block and in fluid communication with the internal gas distribution manifold, which allows the injection block to move at least 150 μm, 300 μm, or more vertically relative to a fixed-position gas distribution system while maintaining a fluid connect between the print die and the injection block

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

A heating element may be used to maintain a temperature within the injection block with a variation of 2 C or less

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

OLEDs make use of thin organic films that emit light when voltage is applied across the device

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentUS12492461B2OVJP injection block

Publication Date: 2025.12.09 UNIVERSAL DISPLAY CORP

AI summary

A deposition device including an injection block and a print die is provided, which allows for vertical movement of the injection block while still maintaining connection between the print die and external gas sources. Also disclosed is an injection block suitable for such devices, which provides improved vertical range of motion and thermal consistency compared to conventional injection block devices.