Using organic materials in making an organic light-emitting device
AssigneeEastman Kodak Company
InventorsSyamal K. Ghosh, Donn B. Carlton, Tukaram K. Hatwar, Steven A. Van Slyke
Life of this patent
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Abstract
A method of making an organic layer from an organic material on a substrate which will form part of an organic light-emitting device, including the steps of providing a sublimable organic material in a powder form; providing a thermally conductive and non-sublimable ceramic material in a powder form; forming a mixture of the sublimable organic material powder and thermally conductive and non-sublimable ceramic material powder; placing such mixture into a die and using a punch to apply sufficient pressure to the heated mixture to cause the mixture of powders to consolidate into a solid pellet; and removing the pellet from the die.
Claims25
A method of making an organic layer from an organic material on a substrate which will form part of an organic light-emitting device, comprising the steps of:
- (a) providing a sublimable organic material in a powder form;
- (b) providing a thermally conductive and non-sublimable ceramic material in a powder form;
- (c) forming a mixture of the sublimable organic material powder and thermally conductive and non-sublimable ceramic material powder;
- (d) placing such mixture into a die and using two opposing punches to apply sufficient pressure to the mixture;
- (e) applying heat to the die during or prior to applying pressure by the opposing punches to aid in causing the mixture of powders to consolidate into a solid pellet;
- and
- (f) removing the pellet from the die.
A method of making solid pellets of sublimable organic material adaptable for making an organic layer on a substrate which will form part of an organic light-emitting device, comprising the steps of:
- (a) providing at least one sublimable organic host material in a powder form;
- (b) providing at least one sublimable organic dopant material in a powder form and as a selected weight fraction of the organic host material;
- (c) forming a first mixture of the at least one organic host material and the at least one organic dopant material;
- (d) providing a thermally conductive and non-sublimable ceramic material in a powder form;
- (e) forming a second mixture of selected portions of the first mixture and the thermally conductive and non-sublimable ceramic material powder;
- (f) placing such mixture into a die and using a two opposing punches to apply sufficient pressure to the mixture;
- (g) applying heat to the die during or prior to applying pressure by the opposing punches to aid in causing the second mixture of powders to consolidate into a solid pellet;
- and
- (h) removing the pellet from the die.
A method of making an organic layer from an organic material on a substrate which will form part of an organic light-emitting device, comprising the steps of:
- (a) providing at least one sublimable organic host material in a powder form;
- (b) providing at least one sublimable organic dopant material in a powder form and as a selected weight fraction of the organic host material;
- (c) forming a first mixture of the at least one organic host material and the at least one organic dopant material;
- (d) providing a thermally conductive and non-sublimable ceramic material in a powder form;
- (e) forming a second mixture of selected portions of the first mixture and the thermally conductive and non-sublimable ceramic material powder;
- (f) placing such second mixture into a die and applying sufficient pressure using two opposing punches to the second mixture in the die;
- (g) applying heat to the die during or prior to applying pressure to by the opposing punches to aid in causing the second mixture of powders in the die to consolidate into a solid pellet;
- (h) removing the pellet from the die;
- (i) placing the pellet into a physical vapor deposition source disposed in a chamber;
- (j) positioning the substrate in the chamber and in a spaced relationship with respect to the source;
- (k) evacuating the chamber to a reduced pressure;
- and
- (l) applying heat to the source to cause a portion of the pellet to sublime to provide a vapor of the first mixture of organic materials from which the organic layer is made on the substrate.
Dependencies are inferred from the claim text.