Oleds for micro transfer printing

Abstract

An organic light-emitting diode (OLED) structure includes an organic light-emitting diode having a first electrode, one or more layers of organic material disposed on at least a portion of the first electrode, and a second electrode disposed on at least a portion of the one or more layers of organic material. At least a portion of a tether extending from a periphery of the organic light-emitting diode. The organic light-emitting diodes can be printable organic light-emitting diode structures that are micro transfer printed over a display substrate to form a display.

1 - 40 . (canceled) 
     
     
         41 . A method of making an OLED structure, comprising:
 providing a source substrate;   patterning a sacrificial layer on the source substrate;   patterning a first electrode on the sacrificial layer;   patterning one or more layers of organic material on at least a portion of the patterned first electrode; and   patterning a second electrode on at least a portion of the one or more layers of organic material to form an OLED structure.   
     
     
         42 . The method of  claim 41 , comprising removing at least a portion of the sacrificial layer, thereby partially releasing the OLED structure from the source substrate. 
     
     
         43 . The method of  claim 42 , comprising micro transfer printing the OLED structure from the source substrate to a display substrate. 
     
     
         44 . The method of  claim 41 , wherein the one or more layers of organic material are one or more layers of organic material that emit blue light and the OLED structure is a blue OLED structure that emits blue light when a current is applied thereto. 
     
     
         45 . The method of  claim 44 , comprising:
 forming a red OLED structure that emits red light when a current is applied thereto, comprising:
 providing a second source substrate; 
 patterning a second sacrificial layer on or in the second source substrate; 
 patterning a first electrode on the second sacrificial layer; 
 patterning one or more layers of organic material that emit red light on at least a portion of the patterned first electrode on the second sacrificial layer; and 
 patterning a second electrode on at least a portion of the one or more layers of organic material that emit red light; and 
   forming a green OLED structure that emits green light when a current is applied thereto, comprising:
 providing a third source substrate; 
 patterning a third sacrificial layer on or in the third source substrate; 
 patterning a first electrode on the third sacrificial layer; 
 patterning one or more layers of organic material that emit green light on at least a portion of the patterned first electrode on the third sacrificial layer; and 
 patterning a second electrode on at least a portion of the one or more layers of organic material that emit green light. 
   
     
     
         46 . The method of  claim 45 , comprising:
 micro transfer printing the red OLED structure from the red source substrate to a display substrate;   micro transfer printing the green OLED structure from the green source substrate to the display substrate; and   micro transfer printing the blue OLED structure from the blue source substrate to the display substrate.   
     
     
         47 . The method of  claim 45 , wherein at least ten thousand, one-hundred thousand, one million, or ten million OLEDs are on each source substrate. 
     
     
         48 . The method of  claim 41 , wherein patterning the one or more layers of organic material on the patterned first electrode comprises depositing the layers of organic material through a fine metal shadow mask. 
     
     
         49 . The method of  claim 41 , wherein patterning the one or more layers of organic material on the patterned first electrode and patterning the second electrode on the one or more layers of organic material comprises:
 blanket depositing the layers of organic material over an area of the source substrate;   blanket depositing the second electrode over the layers of organic material;   forming a patterned protective layer over the second electrode, the patterned protective layer defining the pattern of the one or more layers of organic material;   patterning the second electrode by exposing the second electrode to an active material that removes second electrode material exposed to line-of-flight of the active material; and   patterning the one or more layers of organic material by exposing the one or more layers of organic material to an active material that removes the one or more layers of organic material exposed to the line-of-flight of the active material.   
     
     
         50 . The method of  claim 49 , wherein patterning the one or more layers of organic material on the patterned first electrode and patterning the second electrode on the one or more layers of organic material comprises:
 removing the patterned protective layer.   
     
     
         51 . The method of  claim 50 , wherein patterning the one or more layers of organic material on the patterned first electrode and patterning the second electrode on the one or more layers of organic material comprises:
 providing additional patterned second electrode material to form the patterned second electrode and protect the one or more layers of organic material.   
     
     
         52 . The method of  claim 41 , wherein the organic light-emitting diode is a top emitter. 
     
     
         53 . The method of  claim 41 , wherein the organic light-emitting diode is a bottom emitter. 
     
     
         54 . The method of  claim 41 , wherein the organic-light emitting diode a light-emissive area of less than 1600 square microns. 
     
     
         55 . The method of  claim 41 , wherein the organic-light emitting diode has at least one of a width from 5 to 10 μm, 10 to 20 μm, or 20 to 50 μm, a length from 5 to 10 μm, 10 to 20 μm, or 20 to 50 μm, and a height from 2 to 5 μm, 4 to 10 μm, 10 to 20 μm, or 20 to 50 μm. 
     
     
         56 - 67 . (canceled)