WO2001039288A1 - Method for patterning devices - Google Patents
Method for patterning devices Download PDFInfo
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- WO2001039288A1 WO2001039288A1 PCT/US2000/031989 US0031989W WO0139288A1 WO 2001039288 A1 WO2001039288 A1 WO 2001039288A1 US 0031989 W US0031989 W US 0031989W WO 0139288 A1 WO0139288 A1 WO 0139288A1
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- WO
- WIPO (PCT)
- Prior art keywords
- layer
- patterned die
- portions
- electrode layer
- electrode
- Prior art date
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- 238000000034 method Methods 0.000 title claims abstract description 74
- 238000000059 patterning Methods 0.000 title abstract description 26
- 239000010410 layer Substances 0.000 claims abstract description 153
- 239000012044 organic layer Substances 0.000 claims abstract description 80
- 239000000758 substrate Substances 0.000 claims abstract description 40
- 239000002184 metal Substances 0.000 claims abstract description 27
- 229910052751 metal Inorganic materials 0.000 claims abstract description 27
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- 238000000151 deposition Methods 0.000 claims description 22
- 238000001020 plasma etching Methods 0.000 claims description 14
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- 229910052710 silicon Inorganic materials 0.000 claims description 13
- 238000004519 manufacturing process Methods 0.000 claims description 11
- 238000003825 pressing Methods 0.000 claims description 9
- 150000002739 metals Chemical group 0.000 claims description 4
- 238000003466 welding Methods 0.000 claims description 3
- 229910001092 metal group alloy Inorganic materials 0.000 claims description 2
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- 230000000994 depressogenic effect Effects 0.000 description 14
- 238000012545 processing Methods 0.000 description 12
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- 239000001301 oxygen Substances 0.000 description 3
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- 239000000126 substance Substances 0.000 description 3
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- HIZCTWCPHWUPFU-UHFFFAOYSA-N Glycerol tribenzoate Chemical compound C=1C=CC=CC=1C(=O)OCC(OC(=O)C=1C=CC=CC=1)COC(=O)C1=CC=CC=C1 HIZCTWCPHWUPFU-UHFFFAOYSA-N 0.000 description 1
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- 238000005401 electroluminescence Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
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- 229920002457 flexible plastic Polymers 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 230000005525 hole transport Effects 0.000 description 1
- 238000011031 large-scale manufacturing process Methods 0.000 description 1
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- 230000003287 optical effect Effects 0.000 description 1
- 229920002120 photoresistant polymer Polymers 0.000 description 1
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- 239000011241 protective layer Substances 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
- 238000001878 scanning electron micrograph Methods 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
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- 150000003384 small molecules Chemical class 0.000 description 1
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
- H05B33/10—Apparatus or processes specially adapted to the manufacture of electroluminescent light sources
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/10—OLED displays
- H10K59/17—Passive-matrix OLED displays
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/80—Constructional details
- H10K50/805—Electrodes
- H10K50/81—Anodes
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/80—Constructional details
- H10K50/805—Electrodes
- H10K50/82—Cathodes
- H10K50/826—Multilayers, e.g. opaque multilayers
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
- H10K71/10—Deposition of organic active material
- H10K71/18—Deposition of organic active material using non-liquid printing techniques, e.g. thermal transfer printing from a donor sheet
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
- H10K71/20—Changing the shape of the active layer in the devices, e.g. patterning
- H10K71/231—Changing the shape of the active layer in the devices, e.g. patterning by etching of existing layers
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
- H10K71/60—Forming conductive regions or layers, e.g. electrodes
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/10—OLEDs or polymer light-emitting diodes [PLED]
- H10K50/11—OLEDs or polymer light-emitting diodes [PLED] characterised by the electroluminescent [EL] layers
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
- H10K71/20—Changing the shape of the active layer in the devices, e.g. patterning
- H10K71/221—Changing the shape of the active layer in the devices, e.g. patterning by lift-off techniques
Definitions
- the present invention relates to patterning methods for thin films, and more particularly to patterning methods using a die.
- OLEDs Organic light emitting devices
- OLED configurations include double
- the constituent materials must be patterned.
- Patterning maybe achieved by photoresist methods, as disclosed by U. S . Patent No.5 ,641 ,611 to Shieh, and in U.S. Patent No. 6,013,528 to Burrows et al. Shadow masks may also be used to pattern, as disclosed by co-pending U.S. Patent Application No. 09/182,636. Shadow
- the present invention relates to patterning methods for organic devices, and more
- a first layer of organic materials is deposited
- a first patterned die having a raised portion is then pressed onto the first electrode layer, such that the raised portion of the first
- patterned die contacts portions of the first electrode layer.
- the patterned die is removed, such
- patterned die are removed.
- a second organic layer is then
- a second electrode layer is deposited over the first electrode layer, followed by a second electrode layer.
- patterned die having a raised portion is pressed onto the second electrode layer, such that the
- the patterned die Preferably the patterned die
- Figure 1 shows a cross-section of a die adapted for use with the present invention.
- Figure 2 shows a cross-section of a sample prior to patterning in accordance with the
- Figure 3 shows a cross-section of the die of Figure 1 being used to pattern a sample
- Figure 4 shows a plan view of the sample of Figure 3 after patterning
- Figure 5 shows a patterning process by cold welding followed by lift-off as set forth
- Figure 6 shows optical micrographs of a 230 ⁇ m diameter dots pattern
- Figure 7 shows the results of a comparison of OLEDs patterned by a shadow masking
- Figure 8 shows SEM images of the cross pattern with a width of 55 ⁇ m
- Figure 9 shows optical micrographs of the passive matrix w ith 420 ⁇ m x 420 ⁇ m
- Figure 10 shows CCD camera images of electroluminescence from single and multiple
- Figure 1 1 is a schematic diagram showing elastic deformation of the glass substrate
- Figure 12 shows a device partially fabricated m accordance ⁇ ith an embodiment of
- Figure 13 shows the partially fabricated device of Figure 12 after further processing
- Figure 14 shows the partially fabricated device of Figure 13 after further processing
- Figure 15 shows the partially fabricated device of Figure 14 after further processing.
- Figure 16 shows the partially fabricated device of Figure 15 after further processing.
- Figure 17 shows the partially fabricated device of Figure 16 after further processing.
- Figure 18 shows the partially fabricated device of Figure 17 after further processing
- Figure 19 shows a top view of the device of Figure 18.
- Figure 20 shows an illustration of the connection of metal layers at an edge of a device
- Figure 21 shows the current vs. voltage of actual devices.
- Figure 22 shows the quantum efficiency vs. current of actual devices.
- a method for patterning an electronic device using a die is provided.
- the device is
- patterned layers or a first electrode may be formed on the substrate using techniques known
- top electrode layer is deposited over the organic layer.
- the optional first electrode may be for example, a cathode layer or an anode layer.
- the optional first electrode may be
- the top electrode layer is a cathode
- the electronic device may be for example an Organic Light Emitting Device (OLED)
- the blanket layers are patterned with a die having raised and depressed portions that
- the die is pressed onto the blanket
- top electrode layer may be coated with a material such that the underlying portions of the top electrode layer stick
- top electrode layer are not coated with a material such that the underlying portions of the top electrode layer stick
- the die is formed from a hard substance
- the die is made of a substance
- Silicon, glass, quartz and hard metals Silicon
- Figure 1 shows a cross-section of a die 100 adapted for use with the present invention
- Die 100 has a body 102, formed of a hard substance Body 102 has depressed portions 104
- Depressed portions 104 and raised portions 106 may be formed using
- Coating 108 is adapted to adhere well to body 102
- Coating 108 is also adapted to adhere well to materials such as metal and mdium tin oxide
- coating 108 may be a metal or other pressure sensitn e adhesive In
- Figure 2 shows a cross-section of a sample 200 prior to patterning m accordance with
- Sample 200 has a substrate 202 made of a material adapted to provide
- Support Substrate 202 maybe made of any suitable material, including glass, polymers, and
- plexiglass Substrate 202 may be rigid, flexible, opaque or transparent Preferably, substrate
- a bottom electrode 204 made of a material such as glass or plastic
- conductive material is deposited onto substrate 202 using techniques known to the art
- bottom electrode 204 is made of a transparent conductive mate ⁇ al, such as ITO
- the bottom electrode 204 may be patterned into st ⁇ ps, as discussed m
- Organic layer 206 may comp ⁇ se a single
- organic layer 206 may comp ⁇ se the multiple
- Top electrode layer 208 is blanket
- Top electrode layer 208 is made of a conductive material
- Figure 3 shows a cross-section of die 100 of Figure 1 being used to pattern a sample
- electrode 304, organic layer 306 (comprising regions 306a and 306b) and top electrode layer 308 (comprising top electrode 308a and region 308b) of Figure 3 correspond to substrate 202,
- Die 100 is pressed onto sample 300, and raised portions 106 of die 100 contacts the
- top electrode layer 308 does not stick to the die
- Figure 4 shows one of many possible different plan views of sample 300 after patterning as desc ⁇ bed with reference to Figure 3 In figure 4, a passive display is being
- Figure 3 is a cross-section of Figure 4 through line 3' Bottom
- electrodes 304 are patterned into strips using techniques known to the art, prior to the
- top electrode layer 308 has been patterned to form
- top electrodes 308a Regions 306a are exposed because regions 308b of top electrode layer
- Sample 300 as shown m Figure 4 forms a 3x2
- electronic devices 402, 404, 406, 408, 410 and 412 are a ⁇ ay of electronic devices.
- Each of these electronic may be independently addressed by controlling the voltages of bottom
- organic layer 206 may be made of a material that emits blue light, and patterned
- blue-to-green and blue-to-red down conversion layers maybe deposited on substrate 202 prior
- each pixel comprises three organic devices — one with no down conversion layer that
- the organic layers may emit light through any of a number of mechanisms
- any type of luminescence may be used in any of the embodiments
- patterned such that a cathode layer of the OLED was selectively lifted off of an OLED by pressing a patterned silicon stamp (i.e , a die) with a metal layer, onto the unpattemed OLED.
- a patterned silicon stamp i.e , a die
- the stamp contained a metal coating, which cold
- the glass substrate 602 was precoated with -1500A thick, transparent,
- ITO mdium tin oxide
- the OLED was a single heterostructure device having a 500A thick hole transpoit
- cathode consisted of a 400A thick Mg Ag alloy cathode capped with a 300A thick Ag layer
- a stamp (or die) 500 was formed In forming the stamp, a stamp (or die) 500 was formed.
- silicon wafer was processed using conventional photolithography Using SiO, as a mask, the
- RIE reactive ion etching
- silicon stamp 702 was coated with a metal coating 708 having a 50A thick Cr adhesion layer
- the stamp was pressed onto the unpattemed OLEDs to create the OLED pattern.
- glass substrates 602 having a size of about 10 mm x 10 mm were used.
- ITO layer was not patterned and the maximum force of the pressing was ⁇ 35 kN, corresponding to an average pressure of ⁇ 290MPa.
- the ramp rate was 1 kN/s and the sample
- Figure 7 compares the 1 mm diameter OLEDs patterned by the present technique with
- V 0 is defined as voltage corresponding to current density of 10 mA/cm 2 .
- Figure 7 shows that
- Figures 8a and 8b show a cross pattern with a width of 55 ⁇ m obtained by the present
- the maximum force applied during the pressing was ⁇ 8 kN (i.e., a pressure of -380
- Figures 9a and 9b show the achieved pattern.
- 10a and 10b show CCD camera images of the individually and multiply turned on pixels
- the applied pressure should be high enough to decrease the
- the stress distribution in the cathode layer should also be considered. This problem
- applied pressure should be high enough to decrease the interfacial separation of silver layers
- An optimum pressure was determined to be about 250 MPa to
- the substrate of the device may bend such
- the depressed portion of the die is undesirable, and could lead to the removal of layers that are
- stiffer substrates and lower forces applied to the die are two factors
- substrate may be mounted on a stiff support structure, if desired Still other means may be
- a full color OLED may be fabricated as illustrated in Figures 12-18
- Figure 12 shows a partially fabricated device 1200
- a substrate 1220 has a first
- a blanket organic layer 1230 and a blanket electrode layer 1240 are then blanket
- Figure 13 shows the partially fabricated device 1200 of Figure 12 after further
- patterned die 1210 has been pressed onto device 1200 and remo ⁇ ed
- Removed portion 1240b of blanket electrode layer 1240 has adhered to and been removed by
- First operational organic layer 1230a remains on device 1200, in electrical contact with first
- Second electrode 1240a also remains on device 1200, in electrical contact
- Figure 13 depicts removed portion 1230b of blanket organic layer 1230 adhered to die
- underlying portion 1240b of second electrode layer 1240 may be entirely removed by die
- Figure 14 shows the partially fabricated device 1200 of Figure 13 after further
- portion 1230c may be accomplished by any combination
- portion 1230c includes Alq, which is rapidly
- a thm protective layer of gold may be deposited as a part of
- electrode 1240a to provide protection from the removal process, particularly if reactive ion
- Insulating strips 1227 may prevent the formation of possible shorts between first
- Insulating st ⁇ ps 1227 run parallel to second electrode 1540a, and may be made of any non-
- insulating st ⁇ ps 1227 are
- Insulating strips 1227 may not be necessary, and may be omitted from device 1200, if the formation of such shorts is within acceptable tolerances even without
- Figure 15 shows the partially fabricated device 1200 of Figure 14 after further
- blanket electrode layer 1540 that correspond to raised portions 1512 of die 1510
- Figure 16 shows the partially fabricated device 1200 of Figure 15 after further
- blanket organic layer 1530 remains on device 1200, in electrical contact with first electrode
- Third electrode 1540a remains on device 1200, in elect ⁇ cal contact with second
- Figures 15 and 16 show that die 1510 has depressed portions 1514 above previously
- depressed portion such as depressed portion 1514
- second electrode 1240a minimizes damage to these previously fabricated functioning parts during subsequent stamping procedures. If previously fabricated functioning parts can
- Figure 17 shows the partially fabricated device 1200 of Figure 16 after further
- a blanket organic layer 1730 and a blanket electrode layer 1740 have been
- blanket electrode layer 1740 that correspond to raised portions 1712 of die 1710.
- Figure 18 shows the device 1200 of Figure 17 after further processing, to create a fully
- Fourth electrode 1740a remains on device 1200, in electrical contact with
- Figure 19 shows atop view of the device of Figure 18.
- Figures 12 - 18 are taken from
- second electrode 1240a is
- third electrode 1540a is preferably electrically connected to residual portion 1740d directly above third electrode 1540a This
- 1540d and 1740d are in elect ⁇ cal contact with second electrode 1230 at the edge of device
- Third electrode 1530 is similarly in electrical contact with its overlying residual portion
- portions 1530d and 1730d may also be achieved without the use of edge masking by driving
- Operational organic layers 1230a, 1530a and 1730a emit light when current is passed
- first operational organic layer 1230a emits light when a current is applied between first electrode 1225 and second electrode 1240a.
- organic layer 1530a emits light when a current is applied between first electrode 1225 and
- Operational organic layer 1230a emits light when a current is applied
- operational organic layer 1230a may emit red
- operational organic layer 1530a may emit green light
- additional layers and sublayers may be present.
- additional layers and sublayers may be present.
- additional layers and sublayers may be present.
- additional layers and sublayers may be present.
- operational organic layer 1230a may comprise multiple sublayers as described with respect
- a hole injecting layer may be present.
- a hole injecting layer may be present.
- electrode and an organic layer may block physical contact between the electrode and the
- Figures 12-20 may be practiced using dies, materials, and process
- each of the organic layers and each electrode is about 1000A thick.
- first electrode 1225 is ITO, although any other suitable transparent electrode may be used.
- second electrode 1240a, third electrode 1540a, and fourth electrode 1240a are used.
- second electrode 1240a, third electrode 1540a, and fourth electrode 1240a are used.
- 1740a comprise a layer of Mg/Ag alloy about 1000A thick, coated with a layer of Au about
- any suitable electrode may be used, such as a LiF / Al electrode.
- the die should be properly positioned during the
- the die should be positioned accurately with respect to
- optical alignment may be achieved using techniques know to the art, such as optical alignment using
- edge masking may be used during deposition to provide an area
- a 500 A thick layer of ⁇ -NPD was blanket deposited over the ITO,
- the top electrodes (cathodes) of the first array only were then deposited through shadow masks.
- the first array was confined to less than half of the
- lines 2110 and 21 15 of Figure 21 show the current vs. voltage
- lines 2210 and 2215 of Figure 22 show the quantum efficiency vs. current.
- Lines 2120 and 2125 of Figure 21 show current vs. voltage
- substrate including the first array of devices, followed by a second 500 A thick layer of Alq,
- Lines 2150 and 2155 of Figure 21 show current vs voltage, and lines 2250
- the present method is very cost-effective, because the
- stamps are reusable In embodiments where the stamps have metal layers, the stamps are
- the method of the present invention is well suited for roll-to-roll
- operational organic layer 1230a can be different from operational organic layer
- the present invention is not limited to OLEDs, and
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU17864/01A AU1786401A (en) | 1999-11-23 | 2000-11-21 | Method for patterning devices |
EP00980632.4A EP1232531B1 (en) | 1999-11-23 | 2000-11-21 | Method for patterning devices |
JP2001540857A JP4606677B2 (en) | 1999-11-23 | 2000-11-21 | Method for patterning a device |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/447,793 | 1999-11-23 | ||
US09/447,793 US6294398B1 (en) | 1999-11-23 | 1999-11-23 | Method for patterning devices |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2001039288A1 true WO2001039288A1 (en) | 2001-05-31 |
WO2001039288A8 WO2001039288A8 (en) | 2001-11-29 |
Family
ID=23777776
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2000/031989 WO2001039288A1 (en) | 1999-11-23 | 2000-11-21 | Method for patterning devices |
Country Status (8)
Country | Link |
---|---|
US (3) | US6294398B1 (en) |
EP (1) | EP1232531B1 (en) |
JP (1) | JP4606677B2 (en) |
KR (1) | KR100671758B1 (en) |
CN (1) | CN1237627C (en) |
AU (1) | AU1786401A (en) |
TW (1) | TW527739B (en) |
WO (1) | WO2001039288A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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GB2462298A (en) * | 2008-07-31 | 2010-02-03 | Nano Eprint Ltd | Electronic device manufacturing method |
US8100734B2 (en) * | 2002-08-16 | 2012-01-24 | Universal Display Corporation | Organic light emitting devices for illumination |
Families Citing this family (908)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6913713B2 (en) * | 2002-01-25 | 2005-07-05 | Konarka Technologies, Inc. | Photovoltaic fibers |
US6984546B2 (en) * | 2001-03-15 | 2006-01-10 | Delta Optoelectronics, Inc. | Method for forming a thin film light emitting device |
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Also Published As
Publication number | Publication date |
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US6294398B1 (en) | 2001-09-25 |
JP2003515887A (en) | 2003-05-07 |
EP1232531A1 (en) | 2002-08-21 |
TW527739B (en) | 2003-04-11 |
AU1786401A (en) | 2001-06-04 |
JP4606677B2 (en) | 2011-01-05 |
US20020094594A1 (en) | 2002-07-18 |
EP1232531B1 (en) | 2017-05-10 |
US6468819B1 (en) | 2002-10-22 |
EP1232531A4 (en) | 2009-02-11 |
KR100671758B1 (en) | 2007-01-22 |
CN1237627C (en) | 2006-01-18 |
KR20020066399A (en) | 2002-08-16 |
WO2001039288A8 (en) | 2001-11-29 |
US6677174B2 (en) | 2004-01-13 |
CN1399800A (en) | 2003-02-26 |
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