Young-Sam
Park‡
*a,
Kyung-Hoon
Han‡
b,
Jehan
Kim
c,
Doo-Hee
Cho
a,
Jonghee
Lee
a,
Yoonjay
Han
b,
Jong Tae
Lim
a,
Nam Sung
Cho
a,
Byounggon
Yu
a,
Jeong-Ik
Lee
a and
Jang-Joo
Kim
*b
aFlexible Information Device Research Section, Electronics and Telecommunications Research Institute (ETRI), Daejeon, 34129, Republic of Korea. E-mail: s_yspark@etri.re.kr
bDepartment of Materials Science and Engineering, Seoul National University, Seoul, 08826, Republic of Korea. E-mail: jjkim@snu.ac.kr
cLife Science and Materials Chemistry Team, Pohang Accelerator Laboratory, Pohang, 37673, Republic of Korea
First published on 10th November 2016
To date, all deposition equipment has been developed to produce planar films. Thus lens arrays with a lens diameter of <1 mm have been manufactured by combining deposition with other technologies, such as masks, surface treatment, molding etc. Furthermore, a nano-lens array (NLA) with a sufficiently small lens diameter (<1 μm) is necessary to avoid image quality degradation in high resolution displays. In this study, an organic NLA made using a conventional deposition technique – without combining with other techniques – is reported. Very interestingly, grazing-incidence small-angle X-ray scattering (GI-SAXS) experiments indicate that the NLA is formed by the crystallization of organic molecules and the resulting increase in surface tension. The lens diameter can be tuned for use with any kind of light by controlling the process parameters. As an example of their potential applications, we use NLAs as a light extraction film for organic light emitting diodes (OLEDs). The NLA is integrated by directly depositing it on the top electrode of a collection of OLEDs. This is a dry process, meaning that it is fully compatible with the current OLED production process. Devices with NLAs exhibited a light extraction efficiency 1.5 times higher than devices without, which corresponds well with simulation results. The simulations show that this high efficiency is due to the reduction of the guided modes by scattering at the NLA. The NLAs also reduce image blurring, indicating that they increase color stability.
A light extraction layer for organic light emitting diodes (OLEDs) is one of the great applications of lens arrays, since OLEDs have become dominant in small sized displays and are increasingly used in the production of large sized TVs and in solid state lighting. Improving efficiency has always been an important issue in OLEDs so as to reduce power consumption in all of these applications. Light extraction is one of the most important technologies for improving the efficiency of OLEDs, because 60–80% of the generated light is trapped in the OLED as either a substrate confined mode, a waveguided mode or a surface plasmon polariton mode, if there are no extraction films. A large number of methods of integrating either an internal or external light extraction layer or combining both have been developed to enhance the light extraction efficiency and therefore improve the external quantum efficiency.1–50
Despite such developments, light extraction technologies are still not used for display applications because of image blurring issues. For the bottom emission OLEDs used in TVs, image blurring arises from their thick substrates, while for the top-emitting OLEDs (TOLEDs) used in small size displays, difficulties arise from the integration of the light extraction layer. Image blurring issues must also be considered in TOLEDs used for small sized displays, even though the image blurring is less serious, as thin layers (an encapsulation layer and a micro-lens array) on the order of a few micrometers are applied onto the top electrode.51 Most of the light extraction layers fabricated by wet processing are not compatible with the current TOLED manufacturing process. Furthermore, the pixel size of active matrix OLED (AMOLED) displays for mobile devices is continuously decreasing, following increases in image resolution. Thus, NLAs with a sufficiently small size (<1 μm) are necessary to avoid image quality degradation.
The development of a deposition process for creating NLAs which does not use additional techniques and which is compatible with current OLED fabrication technologies is one of the greatest advances in development of high resolution displays with a low cost and short takt time. In this work, we report an organic NLA fabricated using an organic vapor phase deposition (OVPD) method without combination with other techniques. The formation mechanism of the NLA is investigated using grazing-incidence small-angle X-ray scattering (GI-SAXS) analysis. To elucidate the efficacy of the NLA, optical simulations are performed. OLEDs without and with the NLAs are fabricated and characterized.
:
TCTA
:
Ir(ppy)2(acac) (0.46
:
0.46
:
0.08 wt%, 30 nm)/TCTA (10 nm)/TAPC (10 nm)/10 wt% ReO3 doped TAPC (40 nm)/HATCN (40 nm), where B3PYMPM, TCTA, Ir(ppy)2(acac), TAPC, and HATCN represent bis-4,6-(3,5-di-3-pyridylphenyl)-2-methylpyrimidine, 4,4′,4′′-tris(carbazol-9-yl)-triphenylamine, bis(2-phenylpyridyl) iridium(III) acetylacetonate, 1,1-bis-(4-bis(4-methyl-phenyl)-amino-phenyl)-cyclohexane, and 1,4,5,8,9,11-hexaazatriphenylene hexacarbonitrile, respectively. The IZO was sputter deposited onto the HATCN film using facing targets at room temperature. The NLA was fabricated on the IZO by using OVPD. The J–V–L characteristics were measured using a Keithley 2400 programmable source meter. The angular distribution of the electroluminescence intensity was measured using the Keithley 2400 programmable source meter, a rotation stage and an Ocean Optics S2000 fiber optic spectrometer.
Scanning electron microscope (SEM) images of the NLAs fabricated on the IZO layers using the OVPD method are shown in Fig. 1. When the thermal evaporation process was used to fabricate the NPB film, a planar thin film rather than a NLA was obtained. Fig. 1a and b show that hemispherical nano-lenses with a diameter of ∼80 nm (NLA pattern 1) were formed, and that some of the nano-lenses were impinged, as indicated by arrows.
By controlling the fabrication process, including the vaporizer pressure, nano-lenses with a diameter of 200–700 nm (NLA pattern 2) could be fabricated as presented in Fig. 1c and d, indicating that the diameter is controllable by controlling the process parameters. The coverage ratio of nano-lenses to the total surface is ∼70%. These morphologies indicate that islands nucleate in isolated areas and grow larger, impinging other islands.56
The nano-lenses in NLA 2 (which have a larger lens size) have a greater tendency to coalesce compared to the nano-lenses in NLA 1 (which have a smaller lens size). The results in Fig. 1 demonstrate that a size controllable NLA technology is developed using OVPD alone. Size control is an important technique because any kind of light can be chosen by adjusting the nano-lens diameter.
Fig. 2a explains the basic scheme of the GI-SAXS experiments, in which a synchrotron X-ray beam impinges on the specimen with a constant angle of incidence (αi), and the beam is scattered at an out-of-plane angle (αf) and an in-plane angle (2θf).57,58Fig. 2b–d are the GI-SAXS images of the three samples. The red color indicates a high scattering intensity. Fig. 2e and f present the q scan curves of the three specimens. The qxy and qz scan was carried out by cutting a line through the in-plane (qxy), and out-of-plane (qz) direction, respectively, at 2θf = 0°. Sample IZO/PL, deposited by thermal evaporation, has very broad NPB diffraction patterns (Fig. 2c) and q scan peaks (Fig. 2e), suggesting that the NPB molecules are stacked irregularly as an amorphous phase (Fig. 2g). In contrast, in the case of Sample IZO/NLA, the NPB diffraction peaks have sharp hemi-circles around the origin (Fig. 2d) and the q scan peaks are sharp (Fig. 2e and f), suggesting that the NLAs are composed of randomly oriented polycrystalline phases with small NPB crystallites. Thus, the NPB vapors crystallize to form the NLA in the OVPD process, but do not crystallize in the thermal evaporation process, instead forming a planar film.
To further examine the crystalline characteristics of the NPB crystallites in the NLA, the q scan peaks were indexed. The indexing was completed by assuming that there were two different crystals with monoclinic Bravais lattices, and that the organic molecules were positioned at the centers of the monoclinic lattices. The monoclinic system with a β value of 86.62° coincides with qxy values excluding 0.985 and 1.267, and the system with a β value of 87.12° coincides with those excluding 0.836, where β is an angle between the <100> and <001> axes (Table 1). Thus, the stacking is identified as the co-existence of the two monoclinic structure units (Fig. 2h).
| q xy [Å−1] | Monoclinic (β = 86.62°) | Monoclinic (β = 87.12°) |
|---|---|---|
| 0.695 | (010) | (010) |
| 0.836 | (101) | — |
| 0.940 | (100) | (100) |
| 0.985 | — | (101) |
| 1.160 | (110) | (110) |
| 1.267 | — | (111) |
| 1.385 | (020) | (020) |
| 1.600 | (001) | (001) |
The difference in morphology between the films grown by thermal evaporation and OVPD can be explained by the higher surface tension of the crystalline NPB layer compared to the amorphous layer, as explained in Fig. 3. If the surface tension of the substrate (γs) is larger than the sum of those of the thin film and the interface of the substrate-thin film (γt + γst), the thin film grows with a planar morphology (Fig. 3a). If γs is smaller than γt + γst, the thin film grows with an island morphology (Fig. 3b).59,60
The even surface of the NPB layer grown by thermal evaporation on the IZO layer indicates that the sum of γa-NPB and γIZO/a-NPB is smaller than γIZO, where γa-NPB, γIZO/a-NPB, and γIZO are the surface tensions of the amorphous NPB, the interface between the IZO and amorphous NPB, and the IZO, respectively. In fact, the surface tension of the amorphous NPB (γa-NPB, 56.4 dyne per cm (ref. 61)) is reported to be smaller than that of the IZO film (γIZO, 90 dyne per cm (ref. 62)).
In contrast, the island growth of crystalline NBP on IZO by OVPD indicates that the sum of γc-NPB and γIZO/c-NPB is larger than γIZO, where γc-NPB, and γIZO/c-NPB are the surface tensions of the polycrystalline NPB, and the interface between IZO and polycrystalline NPB, respectively. In other words, γc-NPB is supposed to be higher than γa-NPB. This interpretation is supported by the variation in the surface tension depending on the crystallinity of the polymers due to a difference in density as reported before.63 For instance, crystalline polyethylene has a much higher surface tension (66.8 dyne per cm) than amorphous polyethylene (35.7 dyne per cm).63 Thus, the formation mechanism of the NLA can be established as crystallization of the NPB molecules and the resulting increase in surface tension.
The simulation results are summarized in Table 2. Use of NLA 1 and NLA 2 increased the light output efficiency by a factor of 1.02 and 1.48, respectively. The ∼1.5-fold change in the NLA 2 based device is believed to be due to the reduction of the guided modes by scattering at the NLA pattern, which also leads to a decrease in the absorption loss at the interface between the metal and organic layers. However, the light output ratio in the NLA 1 simulation is scarcely changed, which is believed to be due to the small size of the NLA which does not scatter the light efficiently.
| Structure | Extracted | Wave-guided | Absorption by metal | |
|---|---|---|---|---|
| fraction | Enhancement ratio | fraction | fraction | |
| w/o NLA | 0.304 | — | 0.271 | 0.425 |
| w/ NLA1 | 0.311 | 1.02 | 0.261 | 0.428 |
| w/ NLA2 | 0.451 | 1.48 | 0.183 | 0.366 |
The NLA containing nano-lenses with a diameter of several hundred nanometers (NLA 2) was easily integrated in the OLEDs by directly forming the NLA on the IZO top electrode (Fig. 4a). Fig. 4b presents the current density–voltage–luminous (J–V–L) plots of the devices without and with the NLAs. The J–V curves of the elements are similar and the turn-on voltages are the same (2.4 V), indicating that the OVPD process does not damage the device. The element with the NLA clearly shows a higher luminance than the element without the NLA. Fig. 4c displays that the current efficiency of OLEDs without and with the NLAs at 0.1 mA cm−2 is 79 and 123 cd A−1, respectively, showing an increased ratio of 1.55 by employing the NLA. The increased ratio is similar to that in the simulation results, indicating that the NLA is an optically effective scattering medium for OLEDs. Compared to the element without an NLA, the element with an NLA shows less photo image blurring and higher slope variation with the distance from the OLED center (Fig. 4d), indicating that the NLA provides less image blurring and increases color stability. Both devices without and with the NLAs show extremely small variation of color coordinates (Δu′v′: ∼0.002) as the viewing angle changes from 0° to 60°, which is due to the adoption of the IZO top electrode.67 The simulations using NLA 1 are also confirmed by the device data, which shows a 1.03 times increase in the current efficiency by NLA 1 integration.
Targeting the light extraction layer of OLEDs, an NLA possessing nano-lenses with a diameter of several hundred nanometers was fabricated by controlling the process parameters. The presented NLA solves the issues of the non-compatibility and image blurring. The NLA increases the light extraction efficiency by a factor of ∼1.5, agreeing well with simulation results. Thus, the NLA is an optically effective scattering medium for OLEDs. Therefore, this NLA technology opens up the potential for low cost mass production of highly efficient and color stable OLEDs.
Footnotes |
| † Electronic supplementary information (ESI) available: Additional information about refractive indices and extinction coefficients of the Al and IZO utilized for the optical simulations. See DOI: 10.1039/c6nr07798f |
| ‡ Co-first authors. |
| This journal is © The Royal Society of Chemistry 2017 |