In recent years, the proliferation of smart gadgets has increased the demand for information displays; fortunately, organic light-emitting diodes (OLEDs) show great promise for use in display, lighting, and signage contexts. This research demonstrates inkjet printing of dielectric materials to provide maskless emission area patterning and electrical isolation for large-area OLEDs on flexible/rigid indium tin oxide (ITO)-coated substrates, avoiding the need for typical photolithography steps, including etching and lift-off processes. We have studied the impact of impinged droplets' velocity fluctuations, which are measured in relation to their interaction with the substrate, allowing for the determination of the drop diameter and shape. The inkjet parameters, such as pulse waveform, pulse voltage, and pulse width, are controlled to provide consistently repeatable ejection of dielectric ink droplets. The single-step patterning of complex designs with a minimum opening of 18 μm features is successfully printed with high fidelity. The effect of substrate temperature on the printed template/structure size and shape is explored. We have successfully demonstrated an ultralarge-area (120 × 120 mm2) OLED signage application on inkjet-printed dielectric template (IJPDt). Standard small-area OLEDs (4 × 4 mm2) achieved a maximum brightness of 24480 cd m-2 at 10 V and a maximum current efficiency of 17 cd A-1 with a low turn-on voltage of 2.7 V.
Keywords: dielectric template; emission area pattering; inkjet printing; large area flexible OLEDs; low information display; signage.