Thermal Transfer Sublimation for OLED Pattern Formation
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Solution Overview
Problem
Current methods for forming organic light emitting patterns in organic electro-luminescence displays face challenges in achieving high resolution and uniformity due to the limitations of the deposition process using shadow masks and sublimation methods, which result in increased process time, cost, and reduced material deposition efficiency.
Innovation Solution
A method employing a thermal sublimation process without a shadow mask, utilizing a temporal transfer substrate where heat is applied locally through resistor elements to control the sublimation ratio and deposition of organic light emitting materials, allowing for precise transfer of red, green, and blue pixel layers in a single process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If localized heat is applied over a short period of time for high resolution, then resolution is improved, but sublimation ratio increases causing poor deposition quality
Solution Approach 1:
The patent changes the temporal parameter of heating by applying heat over an extended period rather than a short period, while maintaining localized spatial application. This parameter change reduces the sublimation ratio while preserving resolution, resolving the contradiction between high resolution and deposition quality
Solution Approach 2:
The patent employs periodic or pulsed heating action where heat is applied in controlled intervals to specific regions of the transfer substrate. This periodic action allows material to be gradually transferred with reduced sublimation loss, improving deposition quality while maintaining resolution
2Reliability
If slow heating is applied to reduce sublimation ratio, then deposition quality is improved, but resolution decreases
Solution Approach 1:
The patent applies heating locally to specific regions of the transfer substrate rather than uniformly across the entire substrate. This localized heating maintains high resolution by confining the thermal effect to precise areas while the extended duration keeps sublimation ratio low, simultaneously achieving both resolution and deposition quality
3Manufacturing precision
If shadow mask is used for patterning organic emission layer, then pattern formation is achieved, but process time and cost increase
Solution Approach 1:
The patent extracts and removes the shadow mask from the deposition process entirely. Instead of using a physical mask, the invention directly patterns the organic emission layer on the transfer substrate through localized heating and sublimation control, eliminating the time-consuming mask replacement operations while maintaining pattern formation capability
Solution Approach 2:
The patent replaces the mechanical shadow mask system with a thermal field-based patterning approach. By using localized heating to control material transfer, the mechanical mask is substituted with a controllable thermal field, significantly reducing process time and complexity
4Manufacturing precision
If shadow mask is used for patterning, then pattern formation is possible, but material deposition efficiency is reduced
Solution Approach 1:
By removing the shadow mask from the system, the patent eliminates the material that does not reach the substrate due to mask obstruction. This extraction of the masking element allows direct material deposition onto the transfer substrate, significantly improving material utilization efficiency while maintaining pattern formation through controlled localized heating
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 enables the formation of high-resolution organic light emitting patterns with improved deposition efficiency, reduced porosity, and effective material utilization, allowing for the rapid and simplified deposition of durable organic light emitting layers.
Implementation Method 1
a transfer heating step of applying heat to the temporal transfer substrate to transfer the organic light emitting material on the display substrate by sublimation
Implementation Method 2
a first heating step of applying heat to a portion other than a first region of the temporal transfer substrate to remove the first organic light emitting material formed on the portion other than the first region
Data Source
AI summary
A method of forming an organic light emitting pattern of an organic electro-luminescence display according to an exemplary embodiment of the present invention includes preparing a display substrate in which a region where a first organic light emitting material is to be formed is defined, preparing a temporal transfer substrate (TTS) that is a transfer subject on which the first organic light emitting material is to be transferred, forming the first organic light emitting material on the temporal transfer substrate, applying heat to a portion other than a first region of the temporal transfer substrate to remove the first organic light emitting material formed on the portion other than the first region, disposing the temporal transfer substrate and the display substrate to closely face each other, and applying heat to the temporal transfer substrate to transfer the organic light emitting material on the display substrate.