Thermal Transfer Method for Organic Light Emitting Display Devices
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Solution Overview
Problem
Conventional laser-induced thermal imaging processes for organic light emitting display devices face challenges in precisely transferring organic transfer layers onto display substrates due to difficulties in detaching the organic transfer layer from the donor substrate, leading to incomplete or inaccurate layer formation.
Innovation Solution
A thermal transfer method involving a donor member with a base layer, light-to-heat conversion layer, intermediate layer, organic transfer layer, and protecting films, where lasers are used to form and delaminate the organic layer, with a pressing member and monolayer pattern to ensure precise transfer and adhesion control, allowing for improved lamination and luminescent characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional laser induced thermal imaging process is used to transfer organic materials from a donor substrate to a display substrate, then the organic layers can be formed on the display substrate, but the organic transfer layer cannot be easily detached or separated from the donor substrate, leading to imprecise transfer
Solution Approach 1:
The donor substrate is divided into multiple segments: a base layer, a light-to-heat conversion layer, an intermediate layer, and a releasing layer. This segmentation allows the organic transfer layer to be selectively detached from specific layers (through the releasing layer) while maintaining precision transfer to the display substrate.
Solution Approach 2:
A releasing layer is introduced as an intermediary between the intermediate layer and the organic transfer layer. This releasing layer facilitates easy detachment of the organic transfer layer during the transfer process, solving the detachment difficulty while maintaining transfer precision through the controlled laser-induced thermal imaging process.
2Reliability
If air is present during the lamination process, then the process is simpler, but air bubbles or improper adhesion may occur between layers
Solution Approach 1:
Air is removed from the donor substrate before the laser irradiation and lamination process. This preliminary action ensures that no air bubbles are trapped between layers during transfer, guaranteeing reliable layer adhesion and preventing defects in the final device structure.
Solution Approach 2:
The lamination and transfer process is conducted in a vacuum or inert atmosphere environment. This creates an oxygen-free, moisture-free environment that prevents air bubble formation and ensures proper adhesion between the organic transfer layer and the display substrate, while also protecting the organic materials from degradation.
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
The method enables precise transfer of organic layers onto display substrates, enhancing luminescent characteristics such as resolution and contrast by ensuring accurate layer formation and minimizing adhesion issues.
Implementation Method 1
a light-to-heat conversion layer disposed on the base layer
Implementation Method 2
irradiating a first laser onto the donor member to form a preliminary organic layer on the display substrate
Implementation Method 3
removing air from the pressing member to laminate the display substrate and the pressing member to each other
Data Source
AI summary
A thermal transfer method includes a step of forming a donor member having a base layer, a light-to-heat conversion layer disposed on the base layer, an intermediate layer disposed on the light-to-heat conversion layer, an organic transfer layer disposed on the intermediate layer, and a first protecting film disposed over the base layer and contacting at least one edge of the base layer, irradiating a first laser onto the donor member to form a preliminary organic layer on the display substrate, forming a pressing member having a second protecting film and a third protecting film disposed over the second protecting film and contacting at least one edge of the second protecting film, disposing the display substrate within a space formed by the second protecting film and the third protecting film, and irradiating a second laser onto the pressing member to change the preliminary organic layer to an organic layer.