As one of organic electroluminescent (EL) materials, we developed a method of fabricating an ink using low molecular- weight materials with a long emission lifetime for application to the inkjet method. Although the emission lifetime is usually long for low molecular-weight materials, their high manufacturing cost due to the necessity of vapor deposition is a disadvantage. We utilized the low molecular-weight material, tris-(8-hydroxyquinoline) aluminum (Alq3), and investigated its dispersibility in a solvent in which it has low solubility. In addition, we ascertained whether the material could maintain its photoluminescence characteristic under the irradiation of ultraviolet rays by investigating the emission of photoluminescence. Alq3 was crystallized into nanosize crystals, whose surface was then coated with a primary amine by the gas evaporation method. The fabricated ink contained crystals with an average size of 250nm and high dispersibility in tetradecane, in which Alq3 is insoluble. Thus, we made it possible to carry out an inkjet method with low molecular weight EL materials.

We have developed a 17-inch WXGA full-color polymer OLED display by using newly developed ink-jet printing method. On the ink-jet technology, both droplet volume and landing position were precisely controlled pixel by pixel in order to get luminance uniformity. A pixel circuit having Vth variation-cancellation was adopted and the circuit was modified to realize high uniformity and high gray scale reproduction under the short horizontal period operation. Correction on gamma profile difference among RGB OLEDs was achieved by optimizing on configuration between integrated source driver circuit and outer reference voltage circuit in spite of using a common source driver IC having only one gamma profile. Peak control system, that is important for the large size and high luminance display, was utilized and improved image quality on human feeling and actual power consumption. With these efforts a uniform picture with 260,000 colors and wide viewing angle was achieved. It was proved that the ink-jet method was the optimal manufacturing technology for large-size and high-resolution OLED displays. And we found there is no singular problem on the large size OLED display utilized the ink-jet technology.

An ink-jet head using a buckling diaphragm microactuator is described. The microactuator is composed of a silicon substrate, silicon dioxide insulator, nickel heater layer and electro-plated nickel diaphragm. All the edges of the diaphragm are fixed on the substrate and a narrow gap is formed between the diaphragm and the substrate. A nozzle plate is connected to the actuator by an adhesive spacer to get the ink-jet head. An ink chamber is formed by the surfaces of the diaphragm, the nozzle plate, and the side wall of the spacer. When the diaphragm is heated, thermally induced compressive stress causes the diaphragm to buckle rapidly and the diaphragm simultaneously deflects toward the nozzle plate. The deflection raises the pressure in the ink chamber and an ink droplet is then ejected through the nozzle. The head design was carried out using mechanical analysis of a buckling model, and heat transfer simulation. The diaphragm made from nickel is 300 µm diameter and 2 µm-thick. The narrow gap is 0.4 µm. The cathode current density in nickel sulphamate solution used for nickel electro-plating of the diaphragm was 20 mA/cm2. An ink droplet has been ejected with a velocity of 8 m/s while the ink-jet head is operated by heating the diaphragm with a current of 510 mA at 16.6 V for 10 µs at 1.8 kHz.