Abstract: A method for vaporizing organic materials onto a substrate surface to form a film including providing a quantity of organic material into a vaporization apparatus and actively maintaining the organic material in a first heating region in the vaporization apparatus to be below the vaporization temperature. The method also includes heating a second heating region of the vaporization apparatus above the vaporization temperature of the organic material and metering, at a controlled rate, organic material from the first heating region into the second heating region so that a thin cross section of the organic material is heated at a desired rate-dependent vaporization temperature, whereby organic material vaporizes and forms a film on the substrate surface.

Abstract: A method for metering powdered or granular material onto a heated surface to vaporize such material. The method comprises providing a rotatable auger d for receiving powdered or granular material and as the rotatable auger rotates, such rotatable auger translates such powdered or granular material along a feed path to a feeding location. The method also providing at least one opening at the feeding location such that the pressure produced by the rotating rotatable auger at the feeding location causes the powdered or granular material to be forced through the opening onto the heated surface in a controllable manner. The material is agitated or fluidized proximate to the feeding location.

Abstract: A vapor deposition source for depositing organic material includes a boat having a cavity for holding organic material and an aperture plate, having a plurality of spaced apertures, for enclosing the boat. The vapor deposition source also includes a heating element provided in the cavity between the aperture plate and the organic material, and a baffle member in contact with the heating element and having at least three surfaces which absorb energy from the heating element, the first surface redirecting energy to the aperture plate and the second and third surfaces redirecting energy to the boat walls and the organic material.

Abstract: A method of providing a customized one time use vapor deposition source to a user includes a supplier receiving an order from the user; the supplier providing the one time use vapor deposition source to the user, wherein the one time use vapor deposition source includes at least a boat containing the organic material, a heating element, and an aperture plate; and the supplier receiving payment for the one time use vapor deposition source.

Abstract: A method for controlling the deposition of vaporized organic material onto a substrate surface, includes providing a manifold having at least one aperture through which vaporized organic material passes for deposition onto the substrate surface; and providing a volume of organic material and maintaining the temperature of such organic material in a first condition so that its vapor pressure is below that needed to effectively form a layer on the substrate, and in a second condition heating a volume percentage of the initial volume of such organic material so that the vapor pressure of the heated organic material is sufficient to effectively form a layer.

Abstract: A method for controlling the deposition of vaporized organic material onto a substrate surface, includes providing a heating device to produce vaporized organic material; providing a manifold having at least one aperture through which vaporized organic material passes for deposition onto the substrate surface; providing a controller operating independently of the heating device and effective in a first condition for limiting the passage of vaporized organic material through the aperture, and effective in a second condition for facilitating the passage of vaporized organic material through the aperture; and wherein the heating device, or the controller, or both are contiguous to the manifold.

Abstract: A container for vaporizing a solid material includes a housing having side walls, a bottom wall, and a cover enclosing an interior volume. The cover includes at least one aperture to permit egress of vapor efflux from the housing. A heater heats at least a portion of the housing to vaporize the solid material. A baffle disposed between the cover and the solid material prevents a direct line of sight between the solid material and the aperture(s) and is spaced from the cover to control the flow of vaporized material into a region between the baffle and the cover to promote uniformity of vapor efflux from the aperture(s). The ratio of the interior volume to a volume of the region between the baffle and the cover is at least approximately 20:1. The solid material can be an organic material used to form a layer of an organic light-emitting device.

Abstract: A method for vaporizing organic materials onto a surface, to form a film includes providing a quantity of organic material in a fluidized powdered form; metering the powdered organic material and directing a stream of such fluidized powder onto a first member; heating the first member so that as the stream of fluidized powder is vaporized; collecting the vaporized organic material in a manifold; and providing a second member formed with at least one aperture in communication with the manifold that permits the vaporized organic material to be directed onto the surface to form a film.

Abstract: A vapor deposition source for use in vacuum chamber for coating an organic layer on a substrate of an OLED device, includes a manifold including side and bottom walls defining a chamber for receiving organic material, and an aperture plate disposed between the side walls, the aperture plate having a plurality of spaced apart apertures for emitting vaporized organic material; the aperture plate including conductive material which in response to an electrical current produces heat; means for heating the organic material to a temperature which causes its vaporization, and heating the side walls of the manifold; and an electrical insulator coupling the aperture plate to the side walls for concentrating heat in the unsupported region of the aperture plate adjacent to the apertures, whereby the distance between the aperture plate and the substrate can be reduced to provide high coating thickness uniformity on the substrate.

Abstract: A method for vaporizing organic materials onto a substrate surface to form a film including providing a quantity of organic material into a vaporization apparatus and actively maintaining the organic material in a first heating region in the vaporization apparatus to be below the vaporization temperature. The method also includes heating a second heating region of the vaporization apparatus above the vaporization temperature of the organic material and metering, at a controlled rate, organic material from the first heating region into the second heating region so that a thin cross section of the organic material is heated at a desired rate-dependent vaporization temperature, whereby organic material vaporizes and forms a film on the substrate surface.

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: An elongated thermal physical vapor deposition source for vaporizing organic materials in forming an OLED on a structure includes an elongated container for receiving vaporizable organic material, and an elongated vaporization heater sealingly disposed over the container. The vaporization heater includes a plurality of vapor efflux apertures formed along an elongated direction of the heater, and arranged to provide improved uniformity of vapor efflux of vaporized organic material along the elongated direction of the source.