Controlling Drying Conditions in Vacuum for Uniform Film Formation in Inkjet-Printed OLEDs

The drying process of inkjet-printed organic light-emitting diodes (OLEDs) is influenced by both ink properties and external environmental factors, which ultimately affect the film profile. First, we conducted a detailed investigation of the drying time based on changes in the boiling point (BP) of mixed solvents and analyzed the correlation with the film profile. Under atmospheric drying conditions in a nitrogen (N₂) atmosphere, the increased drying time under capillary-driven flow leads to greater particle movement toward the edges, significantly increasing the coffee-ring effect. Additionally, using a high-boiling-point solvent mixture of ethyl 4-methylbenzoate (EMB) and 2-ethylhexyl benzoate (EHB), we produced uniform thin films both between and within pixels (inter and intrapixel uniformity) through a vacuum drying process. In particular, we proposed a drying process model that divides the drying of inkjet pixels into a microfluidic phase and a gelation phase. Through five gelation phase-controlled vacuum drying experiments, the morphology within the pixels was precisely investigated. By sufficiently removing residual solvents after the microfluidic phase and then proceeding with heating, we produced uniform thin films. Furthermore, we fabricated OLED devices using this gelation phase-controlled vacuum drying process, achieving uniform pixel emission and improved device performance.