OLED (Organic Light Emitting Diodes) is a flat light emitting technology, made by placing a series of organic thin films (usually carbon based) between two conductors. When an electrical current is applied, light is emitted. OLEDs can be used to make displays and lighting, with possible applications that span TV sets, computer screens, mobile phones, decorative lighting and more. Since OLEDs emit light they do not require a backlight and so they are thinner than LCD displays, and are also more efficient, simpler to make and boast a better color contrast.
While OLED displays excel in color-contrast and efficiency compared to LCDs, they’ve also proven relatively hard to produce on a large scale. Current evaporation-based production techniques involve a lot of wasted material and risk of defects. OLEDs are also extremely sensitive to moisture and oxygen and therefore must be protected with a high performance encapsulating layer. All of these issues hinder OLEDs’ market takeover, but much work is put into resolving them.
OLED ink-jet printing
Current OLED producing methods rely on evaporation processes, in which the organic materials are deposited onto a glass sheet through a thin metal stencil, also known as a "shadow mask”. This process is problematic, as a significant amount of the material is wasted because it disperses all over the mask, in addition to inherent mask changes which expose the sheet to dust and compromise yields (OLEDs are by nature sensitive to contamination).
Inkjet OLED printing has the desirable ability to allow precision deposits without the use of a mask. It also produces less stray particles, thus boosting yields. These significant advantages make this technology interesting to many companies and virtually all OLED makers have active ink-jet printing development projects.
Inkjet methods form films by discharging the required amount of organic material onto large glass substrates in regular atmospheric conditions. This could be done, for example, by placing OLED pixels on glass or plastic using a portable platform and nozzles. Such methods have the potential to increase yields and lower prices, thus enabling OLED technology to take its deserving place in the market.
Unfortunately, OLED inkjet printing is not yet common, as printing OLED displays is a relatively challenging task for many reasons. A number of layers need to be deposited in pixels (the size of the pixels themselves is defined by the overall resolution the display will have). Being able to place the right number of drops of the active materials into the pixels is a challenge, in addition to developing a process in which the ink dries to deliver flat films of materials in the pixel.
Despite major progress, it is maintained that soluble OLED materials (required for inkjet printing) are less effective than evaporable ones. Ink-Jet printing is also not able to reach the same high densities of evaporation OLED production, which limits its applications for large-area production (TV panels) and not small mobile, VR and wearable OLEDs.
Ink Jet printing is still not used in any commercial OLED display production. But progress in past years have been rapid and some believe that initial OLED TV production using ink jet printing may begin in 1-2 years.
The latest OLED ink jet news:
Earlier this month JOLED unveiled new display prototypes at FineTech Japan. Today we have received this interesting new video from JOLED that shows the displays in action:
In the video you can see all of JOLED's new prototypes. First up is the Automotive demo - JOLED demonstrated two panels, a 12.3" 1920x720 (167 PPI) panel and a 12.2" 1920x1280 (180 PPI) panel. Both are printed on LTPS backplanes (as do the rest of the company's small and medium sized panels). JOLED's latest investors, Denso and Toyoto Tsusho, are both helping the company with its entry into the automotive display market.
Samsung progresses with its inkjet printing OLED technology, to apply it to next-generation monitors and laptops
According to ETNews, Samsung Display has made significant progress with its OLED ink-jet printing process technology, and the company now aims to apply this technology to produce medium-sized panels for OLED laptops and OLED monitors. Samsung may also use this process to produce smaller tablet displays.
It seems that Samsung is aiming to settle on three main next-generation OLED technologies - evaporation (FMM) OLEDs for small-sized display, ink-jet OLED deposition for medium-sized panels and hybrid QD-OLEDs for large-area OLED TV panels. It's other display technologies are QD-LEDs for TVs and Micro-LEDs for next-generation small and large area displays.
So first up is JOLED's first OLED TV panel. The 55" 4K (3840x2160, 80 PPI) panel offers a 120Hz refresh rate and a color gamut of 100% DCI (135% sRGB) and is printed on JOLED's Transparent Amorphous Oxide Semiconductor (TAOS) backplane.
Last month Japan-based printed OLED developer JOLED announced that it will demonstrate new OLED prototypes (including a 55" printed OLED TV) at Finetech Japan, which starts tomorrow (December 5). Today JOLED detailed the new panels it will have on display at the trade show.
So first we have two automotive displays - a 12.3" HD OLED and a 12.2" flexible (curved ) Full-HD OLED. JOLED's latest investors, Denso and Toyoto Tsusho, are both helping the company with its entry into the automotive display market.
China-based display maker CSoT held a ceremony yesterday as it started construction on its upcoming T7 large-area display production fab. The T7 fab, which has a total cost of around 42.7 billion Yuan ($6.15 billion USD), will produce both LCD and OLED display.
Total capacity in the T7 line will be 105,000 monthly substrates (according to our information, the OLED capacity will be 20,000 monthly substartes). The T7 OLED line will use IGZO backplanes and inkjet printing deposition. CSoT's plan is to start production by the end of 2020 - with real mass production starting in 2021.
BOE is hosting its Global Innovation Partner Conference 2018 (BOE IPC-2018, which invited experts from all over the world to see BOE's latest technology and future trends.
During the event, BOE unveiled an ink-jet printed 55" UHD OLED TV prototype. This is the first time that BOE demonstrated an ink-jet printed TV (in May 2018 BOE unveiled 5.5" FHD flexible AMOLED which was also produced using a printing process).
Japan-based printed OLED developer JOLED announced that it will demonstrate a 55" 4K printed OLED TV at Finetech Japan 2018 (December 5-7 2018). JOLED will also introduce its proprietary printed OLED manufacturing technology. A few weeks ago JOLED announced that it has signed an agreement to develop, manufacture, and sell printing equipment together with Panasonic and Screen Finetech.
This is the first time JOLED will show a 55" OLED prototype (in July 2018 the company did include TVs in its future roadmap). JOLED tells us that it has no plans to produce large size OLEDs at this stage - and this TV is on display just to demonstrate JOLED's printing technology.
Samsung Display is developing hybrid QD-OLED TV technology, and according to estimates, the company aims to begin trial production in 2019. It is also estimated that Samsung has several challenges to overcome, but according to new reports from Digitimes, Samsung is aiming to start installing equipment for the new fab as early as December 2018.
The new fab will begin operation in the second half of 2019 - pilot production at first which will be expanded to full scale mass production. The new fab will be built in Samsung's L8 LCD production line in Asan, and will take over one of the two lines currently in operation at the fab. Samsung's initial production capacity will be around 25,000 monthly G8 substrates.
AUO to establish an OLED ink-jet production line, to make OLEDs for monitors and automotive applications
According to reports from China, Taiwan-based AU Optronics decided to establish an inkjet OLED production line that will be used to produce OLED monitor displays and OLEDs for automotive applications.
The new OLED line will use production equipment made by Japan's JOLED - who started commercial low-volume production of its own 21.6" 4K OLED panels, at the company's pilot 4.5-Gen line. JOLED also announced plans for a mass production 5.5-Gen line that will be established in Nomi City, Ishikawa Prefecture, by 2020, and similarly to AUO, it is focusing on monitors and automotive applications.
The EU-funded Flexolighting project believes that OLED lighting cost can be reduced to 1 Euro per 100 lumens
In 2015, the EU launched the €4.4 million Flexolighting project (led by Brunel University London) with an aim to develop new materials, processes and methods to overcome current OLED lighting challenges - including lifetime, lighting uniformity and more.
The project's consortium announced that following the project completion and a rethinking of the complete OLED supply chain, it believes that high efficiency OLED lighting panels can be produced at a cost that is on a similar level with LED lighting.