Apparatus and methods for depositing one or more organic materials on a substrate

A method for depositing an organic material onto a substrate, comprising:

• (i) providing an apparatus, comprising a source for directing organic material in substantially collimated vapor form;
• a substrate material positioned for receiving portions of the organic material;
• and a pixel mask comprising one or more openings disposed between the source and substrate;
• and,
• (ii) directing the organic material from the source such that portions of the organic material can pass through openings of the collimation mask in substantially collimated form, while other portions impinge upon a surface of the collimation mask and are thereby blocked from passing onward toward the substrate.

A method for depositing at least one organic material onto a substrate, comprising:

• (i) providing an apparatus, comprising a source for directing organic material in substantially collimated vapor form;
• a substrate material positioned for receiving portions of the organic material;
• and a pixel mask comprising one or more openings disposed between the source and substrate;
• and,
• (ii) passing portions of substantially collimated organic material emanating from the source through respective openings of the pixel mask, and impinging other portions of the organic material upon a surface of the pixel mask such that the other portions are thereby blocked from passing onward toward the substrate.

A device for depositing one or more organic materials onto an OLED display substrate in a desired pattern, comprising:

• a) a manifold and an OLED display substrate in a chamber at reduced pressure and spaced relative to each other;
• b) a structure sealingly covering one surface of the manifold, the structure including a plurality of nozzles or openings extending through the structure into the manifold, c) a pixel mask disposed between the substrate and nozzles, wherein the pixel mask defines openings which are spaced from each other and configured in correspondence with the desired pattern of organic material to be deposited onto the OLED display substrate;
• d) a vapor evaporation apparatus for providing vaporized organic material into the manifold;
• and e) a system for applying an inert gas under pressure into the manifold so that the inert gas provides a gas flow through each of the nozzles, such gas flow transporting at least portions of the vaporized organic materials from the manifold through the nozzles to provide collimated beams of the inert gas and of the vaporized organic materials and projecting the collimated beams onto the OLED display substrate for depositing the organic materials in the desired pattern on the substrate.

A device for depositing one or more organic materials onto an OLED display substrate in a desired pattern, comprising:

• a) a chamber at reduced pressure;
• b) an OLED display substrate disposed in the chamber;
• c) a collimating mask comprising a plurality of openings extending there through disposed in the chamber, spaced apart from the substrate,
• d) a pixel mask disposed between the substrate and the collimating mask, wherein the pixel mask defines openings which are spaced from each other and configured in correspondence with the desired pattern of organic material to be deposited onto the substrate;
• and
• e) a vapor evaporation source for directing vaporized organic material towards the collimating mask;
• wherein at least portions of vaporized organic materials emanating from the source can pass through the openings of the collimating mask to provide collimated beams of the vaporized organic materials, and wherein at least portions of the collimated beams can pass through the openings of the pixel mask to be projected onto the substrate for depositing the organic materials in the desired pattern on the substrate.