Multi-layer transfer and lamination (MTL) process assisted by a high-pressure air jet for highly efficient...

Area of Science:

• Materials Science
• Organic Electronics
• Device Fabrication

Background:

• Polymer light-emitting diodes (PLEDs) are crucial for flexible and large-area displays.
• Traditional PLED fabrication methods can be complex and costly.
• Developing efficient and scalable fabrication techniques is essential for commercialization.

Purpose of the Study:

• To report a novel thermally activated multi-layer transfer and lamination (MTL) process for fabricating highly efficient PLEDs.
• To demonstrate the effectiveness of a custom high-pressure air jet system for multi-layer delamination.
• To achieve high-quality PLED devices with excellent performance characteristics.

Main Methods:

• Sequential deposition of PLED layers (light-emitting polymer, electron transport/injection, cathode) onto a self-assembled monolayer (SAM)-coated glass.
• Rapid delamination of the multi-layer stack using a high-pressure air jet.
• Thermally activated lamination of the PLED stack onto a target substrate (hole transport layer/anode) using a polyamide (PA)/polyethylene terephthalate (PET) protective layer.

Main Results:

• The MTL process successfully fabricated high-quality PLED multi-layers without buckling or cracks.
• The fabricated PLEDs achieved a maximum brightness of 13,120 cd m⁻² at 8.4 V.
• Maximum current efficiency and power efficiency were recorded at 5.2 cd A⁻¹ and 4.0 lm W⁻¹, respectively.

Conclusions:

• The thermally activated MTL process is a viable and efficient method for PLED fabrication.
• The custom air jet delamination ensures high multi-film quality.
• This technique offers a promising route for scalable and high-performance PLED manufacturing.