OLED Manufacturing on Flexible Substrates Towards Roll-to-Roll
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MRS Advances © 2019 Materials Research Society DOI: 10.1557/adv.2019.62
OLED Manufacturing on Flexible Substrates Towards Roll-to-Roll Dongxiang Wang, Jacqueline Hauptmann, Christian May Fraunhofer Institute for Organic Electronics, Electron Beam and Plasma Technology (FEP), Winterbergstr. 28, 01277 Dresden, Germany
ABSTRACT
Large area lighting OLEDs manufactured in a Roll-to-Roll (R2R) fashion enable the welllonged production capability with considerably high throughput based on flexible substrates, hence largely reduced OLED manufacturing cost. This paper will outline the present status of R2R OLED fabrication on ultra-thin glass with the focus on transparent OLED devices and how to perform segmentation by printing of silver- and dielectric pastes. Ultra-thin glass (UTG) is laminated on a PET film to avoid fabrication interruptions when glass cracks occur during the Roll-to-Roll process. The R2R fabricated flexible OLEDs also show key-values comparable to conventional OLEDs fabricated on small rigid glass in lab-scale.
INTRODUCTION The biggest obstacle to start Roll-to-Roll mass production for OLED lighting application is the required high OLED device lifetime on plastic barrier films, because OLED devices are very sensitive to moisture and oxygen and claim encapsulation properties 5 orders of magnitude higher than for food packaging. Ultra-thin glass has a high potential for bendable and reliable OLED lighting devices for mass market applications. Flexible ultra-thin glass provided on coils by closecollaborating industry-leading glass manufacturers allows cost effective mass production in Roll-to-Roll. The advantage of flexible glass is that no further barrier film coatings are needed to reach the required barrier requirements for OLED devices. For the minimization of glass breakage, the ultra-thin glass is laminated on a host PET film to increase the robustness during the Roll-to-Roll process. In general, this glass PET laminate supports the tool enhancement to find proper web tensions and critical bending radii for winding pure ultra-thin glass afterwards. Finally, the scratch protection and robustness of the OLED devices will be improved by lamination of transparent ceramic layers at a later stage, which is not presented in this work.
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EXPERIMENTAL
Roll-to-roll processing As the substrate ITO coated ultra-thin flexible glass is used. Patterning of the substrate is done by printing as additive processing. All printings for electrical segmentation through structured isolation of anode by applying a dielectric resin are performed with a R2R flexographic printing process under a printing speed of 0.2 – 0.8 m/min. For curing of the dielectrics a mercury UV lamp is implemented. This patterning process is performed before the OLED stack deposition on the substrate. Roll-to-Ro
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