# US 2014/0197385 A1 · High Resolution Organic Light-Emitting Diode Devices, Displays, and Related Methods

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- Number: US 2014/0197385 A1
- Document ID: US20140197385A1
- Status: Published application
- Kind: A1
- Application number: 14/030,776
- Filed: 2013-09-18
- Published: 2014-07-17
- Earliest claimed: 2013-01-17
- Assignees: Kateeva, Inc.
- Applicants: Kateeva, Inc.
- Inventors: Conor Francis Madigan
- Web page: https://patentgrep.com/patent/US20140197385A1

## CPC

- H10K 59/353: {characterised by the geometrical arrangement of the RGB subpixels}
- H10K 50/11: characterised by the electroluminescent [EL] layers
- H10K 50/15: Hole transporting layers
- H10K 59/122: Pixel-defining structures or layers, e.g. banks
- H10K 71/135: {using ink-jet printing}
- H10K 59/121: characterised by the geometry or disposition of pixel elements
- H10K 2102/00: Constructional details relating to the organic devices covered by this subclass
- H10K 2102/103: {comprising indium oxides, e.g. ITO}
- H10K 2102/351: {Thickness}
- H10K: ORGANIC ELECTRIC SOLID-STATE DEVICES

## Abstract

A method of manufacturing an organic-light emitting diode (OLED) display can include providing on a substrate a first electrode associated with a first sub-pixel and a second electrode associated with a second sub-pixel, wherein a gap is formed between the first electrode and the second electrode and wherein the first electrode and the second electrode are positioned in a well having boundaries defined by a confinement structure on the substrate. The method can also include depositing in the well with the electrodes positioned therein, active OLED material to form a substantially continuous layer of active OLED material that spans the boundaries of the well such that a surface of the layer of active OLED material that faces away from the substrate has a non-planar topography. The depositing can be via inkjet printing.

## Claims

### Claim 1

A method of manufacturing an organic light-emitting diode (OLED) display comprising:
providing on a substrate a first electrode associated with a first sub-pixel and a second electrode associated with a second sub-pixel, wherein a gap is formed between the first electrode and the second electrode and wherein the first electrode and the second electrode are positioned in a well having boundaries defined by a confinement structure on the substrate; and
depositing in the well with the electrodes positioned therein, active OLED material to form a substantially continuous layer of active OLED material that spans the boundaries of the well such that a surface of the layer of active OLED material that faces away from the substrate has a non-planar topography, wherein the depositing is via inkjet printing.

### Claim 2 (depends on 1)

The method of claim 1, wherein the layer of active OLED material has a substantially uniform thickness.

### Claim 3 (depends on 2)

The method of claim 2, wherein the layer of active OLED material includes local non-uniformities in thickness.

### Claim 4 (depends on 3)

The method of claim 3, wherein the local non-uniformities in thickness are within 5 μm-10 μm of edges of surface features in the well.

### Claim 5 (depends on 1)

The method of claim 1, the layer of active OLED material has a thickness less than a thickness of the first electrode and the second electrode.

### Claim 6 (depends on 1)

The method of claim 1, wherein the active OLED material comprises light-emissive material.

### Claim 7 (depends on 6)

The method of claim 6, wherein the light-emissive material has a light-emissive wavelength range that is the same for the first sub-pixel and the second sub-pixel.

### Claim 8 (depends on 1)

The method of claim 1, wherein the layer of active OLED material comprises two layers of active OLED materials including a light-emissive material and a hole conducting material.

### Claim 9 (depends on 8)

The method of claim 8, wherein the hole conducting material is at least one of a hole injecting material and a hole transporting material.

### Claim 10 (depends on 1)

The method of claim 1, wherein the first and second sub-pixels correspond to differing pixels.

### Claim 11 (depends on 1)

The method of claim 1, further comprising providing a structure on the substrate within the gap between the first electrode and the second electrode.

### Claim 12 (depends on 11)

The method of claim 11, wherein the structure comprises an electrically resistive material.

### Claim 13 (depends on 1)

The method of claim 1, further comprising depositing a definition layer on the substrate and a portion of the first electrode and the second electrode and then depositing the confinement structure over the definition layer.

### Claim 14 (depends on 13)

The method of claim 13, wherein the definition layer comprises an electrically resistive material.

### Claim 15 (depends on 13)

The method of claim 13, further comprising depositing a structure on the substrate in the gap between the first electrode and the second electrode.

### Claim 16 (depends on 15)

The method of claim 15, further comprising depositing a second definition layer on the structure.

### Claim 17 (depends on 1)

The method of claim 1, wherein the organic light-emissive display is a top emission display.

### Claim 18 (depends on 1)

The method of claim 1, wherein the display has a fill factor greater than 40%.

### Claim 19 (depends on 1)

The method of claim 1, wherein the display has a fill factor greater than 60%.

### Claim 20 (depends on 1)

The method of claim 1, wherein the display has a resolution of at least 100 ppi.

### Claim 21 (depends on 1)

The method of claim 1, wherein the display has a resolution of at least 300 ppi.

### Claim 22

An organic light-emitting diode (OLED) display, comprising:
a first electrode disposed on a substrate, wherein the first electrode is associated with a first sub-pixel;
a second electrode disposed on the substrate and spaced from the first electrode to provide a gap between the first and second electrodes, wherein the second electrode is associated with a second sub-pixel;
a confinement structure positioned on the substrate to define boundaries of a well containing the first electrode and the second electrode; and
a substantially continuous active OLED material layer that spans the boundaries of the well and is disposed over the first electrode and second electrodes, wherein a surface of the active OLED material layer that faces away from the substrate has a non-planar topography.

### Claim 23 (depends on 22)

The display of claim 22, wherein the active OLED material layer has a substantially uniform thickness.

### Claim 24 (depends on 23)

The display of claim 23, wherein the active OLED material layer includes local non-uniformities.

### Claim 25 (depends on 24)

The display of claim 24, wherein the local non-uniformities in thickness are within 5 μm to 10 μm of edges of surface features in the well.

### Claim 26 (depends on 22)

The display of claim 22, wherein the active OLED material layer has a thickness less than a thickness of the first electrode and the second electrode.

### Claim 27 (depends on 22)

The display of claim 22, wherein the active OLED material layer comprises a light-emissive material.

### Claim 28 (depends on 27)

The display of claim 27, wherein the light-emissive material has a light-emissive wavelength range that is the same for the first sub-pixel and the second sub-pixel.

### Claim 29 (depends on 22)

The display of claim 22, wherein the active OLED material layer comprises two active OLED material layers including a light-emissive material layer and a hole conducting material layer.

### Claim 30 (depends on 29)

The display of claim 29, wherein the hole conducting material is chosen from at least one of a hole injecting material and a hole transporting material.

### Claim 31 (depends on 22)

The display of claim 22, wherein the first and second sub-pixels correspond to differing pixels.

### Claim 32 (depends on 22)

The display of claim 22, further comprising a structure disposed on the substrate within the gap between the first electrode and the second electrode.

### Claim 33 (depends on 32)

The display of claim 32, wherein the structure comprises an electrically resistive material.

### Claim 34 (depends on 22)

The display of claim 22, further comprising a definition layer disposed on the substrate over a portion of the first electrode and the second electrode, wherein the confinement structure is disposed over the definition layer.

### Claim 35 (depends on 34)

The display of claim 34, wherein the definition layer comprises an electrically resistive material.

### Claim 36 (depends on 34)

The display of claim 34, further comprising a structure disposed on the substrate in the gap between the first electrode and the second electrode.

### Claim 37 (depends on 36)

The display of claim 36, further comprising a second definition layer disposed over the structure.

### Claim 38 (depends on 22)

The display of claim 22, wherein the display is a top emission display.

### Claim 39 (depends on 22)

The display of claim 22, wherein the display is an active matrix device.

### Claim 40 (depends on 22)

The display of claim 22, wherein the display has a fill factor greater than 40%.

### Claim 41 (depends on 22)

The display of claim 22, wherein the display has a fill factor greater than 60%.

### Claim 42 (depends on 22)

The display of claim 22, wherein the display has a resolution of at least 100 ppi.

### Claim 43 (depends on 22)

The display of claim 22, wherein the display has a resolution of at least 300 ppi.