Abstract: A method of depositing a patterned organic layer includes providing a manifold and an OLED display substrate in a chamber at reduced pressure and spaced relative to each other; providing a structure sealingly covering at least one surface of the manifold, the structure including a plurality of nozzles extending through the structure into the manifold. The method also includes delivering vaporized organic materials into the manifold, and applying an inert gas under pressure into the manifold so that the inert gas provides a viscous gas flow through each of the nozzles, such viscous gas flow transporting at least portions of the vaporized organic materials from the manifold through the nozzles to provide directed beams of the inert gas and of the vaporized organic materials and projecting the directed beams onto the OLED display substrate for depositing a pattern of an organic layer on the substrate.

Abstract: A new use for a structure including a plurality of nozzles extending through the structure, and the nozzles being spaced from each other in correspondence with the pattern to be deposited onto an OLED display substrate so that vaporized organic material is transported through the nozzles in a desired pattern for deposition onto the OLED display substrate.

Abstract: A thermal physical vapor deposition source for depositing material onto a substrate includes an elongated container for receiving the material, the container having a conductance CB in the elongated direction, and a heater for heating the material in the container to vaporize the material to a partial pressure Pm. The container has at least one member defining a plurality of apertures arranged along the length of the member, the apertures having a total conductance CA, wherein C A C B ? 0.5 ; and end heaters for heating each side of the container to reduce condensation of material onto the container.

Abstract: A thermal physical vapor deposition source for vaporizing compacted pellets of organic materials onto a surface of a substrate in forming a display, including a housing defining a plurality of spaced passages each for receiving compacted pellets, a cover plate over the housing, with a first plurality of openings corresponding to the spaced passages of the housing and an electrical heater structure disposed over the cover plate. The thermal physical vapor deposition source further including an aperture plate, disposed over the electrical heater structure, an electrically insulating spacer member located between the electrical heater structure and an aperture plate, and circuitry for applying current to the electrical heater structure to produce heat sufficient to vaporize the pellets and permit vapor efflux of materials to pass through the cover plate, the heater structure, the electrically insulating spacer member and the aperture plate, onto the substrate.

Abstract: The need is met according to the present invention by providing a method of designing a system for thermal vapor deposition that includes a material to be deposited on a workpiece, an elongated container for containing the material, a heater for heating the material in the container to vaporize the material, the container defining n apertures for emitting the vaporized material in an elongated pattern in the elongated direction, that includes the steps of: calculating the total source throughput Q per unit length at a deposition rate of interest; calculating the internal pressure P of the source required to produce Q for the total aperture conductance CA of the source; modeling the system as a ladder network of conductances, the elongated container having a container conductance CB and conductances Cb=nCB, between apertures, and the apertures having a combined conductance 1 C A = ∑ i = 1 n ⁢   ⁢ C ai ,

Abstract: A method of depositing a patterned organic layer includes providing a manifold and an OLED display substrate in a chamber at reduced pressure and spaced relative to each other; providing a structure sealingly covering at least one surface of the manifold, the structure including a plurality of nozzles extending through the structure into the manifold. The method also includes delivering vaporized organic materials into the manifold, and applying an inert gas under pressure into the manifold so that the inert gas provides a viscous gas flow through each of the nozzles, such viscous gas flow transporting at least portions of the vaporized organic materials from the manifold through the nozzles to provide directed beams of the inert gas and of the vaporized organic materials and projecting the directed beams onto the OLED display substrate for depositing a pattern of an organic layer on the substrate.

Abstract: A new use for a structure including a plurality of nozzles extending through the structure, and the nozzles being spaced from each other in correspondence with the pattern to be deposited onto an OLED display substrate so that vaporized organic material is transported through the nozzles in a desired pattern for deposition onto the OLED display substrate.