Multi-layer transfer and lamination (MTL) process assisted by a high-pressure air jet for highly efficient solution-processed polymer light emitting diodes

This research reports fabrication of highly efficient polymer light-emitting diodes (PLEDs) by a thermally activated multi-layer transfer and lamination (MTL) process. As the first stage of the fabrication process, multiple layers consisting of a light-emitting polymer, electron transport/electron injection layer and metal cathode were sequentially deposited onto a hydrophobic low-surface energy self-assembled monolayer (SAM)-coated glass substrate. Subsequently, a very rapid delamination of PLEDs multi-layers from the SAM-coated glass was achieved by applying a high-pressure air jet. The custom air jet system ensures the excellent multi-film quality and also prevents the occurrence of common buckling and cracks. In addition, the adhesiveness of polyamide (PA) onto polyethylene terephthalate (PET), which serves as a protective barrier from atmospheric water and oxygen, is thermally activated by heating PA above its glass transition temperature. Finally, once delaminated from the PA/PET, the multi-layer structure (light-emitting polymer/electron transport layer/electron injection layer/metal cathode) was successfully laminated onto the target glass (hole transport layer/transparent anode) with a soft roller under mild pressure for the realization of the PLED device. The maximum brightness of the device fabricated by a thermally activated lamination process was around 13 120 cd m^-2 at 8.4 V, whereas the maximum current efficiency and the power efficiency were 5.2 cd A^-1 and 4.0 lm W^-1, respectively.