System and method of transfer printing an organic semiconductor

Abstract

The present invention provides a substrate having thereon a patterned small molecule organic semiconductor layer. The present invention also provides a method and a system for producing a substrate having thereon a patterned small molecule organic semiconductor layer. The substrate having thereon a patterned small molecule organic semiconductor layer is produced by exposing a donor substrate having thereon a small molecule organic semiconductor layer to energy to cause the thermal transfer of a small organic molecule onto an acceptor substrate.

1 . A system for producing a substrate having thereon a patterned small molecule organic semiconductor layer comprising:
 a donor substrate having thereon a small molecule organic semiconductor layer;   an acceptor substrate positioned to receive said patterned small molecule organic semiconductor layer upon exposing said donor substrate to energy; and   an energy source to produce said energy to cause the sublimation and deposition of a small organic molecule onto said acceptor substrate.   
     
     
         2 . The system of  claim 1 , further comprising:
 an energy absorbing film interposed between said donor substrate and said small molecule organic semiconductor layer to absorb said energy and cause thermal transfer of said small organic molecule.   
     
     
         3 . The system of  claim 1 , wherein said small molecule organic semiconductor layer is produced by at least partial conversion of a precursor of the small organic molecule during said exposing of said donor substrate. 
     
     
         4 . The system of  claim 3 , further comprising:
 a heating source to anneal said acceptor substrate after said deposition of said patterned small molecule organic semiconductor layer on said acceptor substrate, wherein said annealing is at about the thermal decomposition temperature of said precursor to convert any remaining precursor to said small organic molecule.   
     
     
         5 . The system of  claim 1 , further comprising:
 means for relatively moving said donor substrate, said acceptor substrate, said energy source, or a combination thereof.   
     
     
         6 . The system of  claim 1 , further comprising:
 a mask, wherein said mask is interposed between said donor substrate and said acceptor substrate.   
     
     
         7 . The system of  claim 1 , wherein said donor substrate is a rigid or flexible ribbon. 
     
     
         8 . The system of  claim 7 , wherein said ribbon is part of a reel to reel apparatus. 
     
     
         9 . The system of  claim 1 , wherein said donor substrate is a disk mounted on a rotatable axis. 
     
     
         10 . The system of  claim 1 , wherein said donor substrate is in the shape of a hollow cylindrical roller having an inner and an outer surface, said outer surface having thereon said small molecule organic semiconductor layer. 
     
     
         11 . The system of  claim 1 , wherein said energy source is disposed at a point within a hollow cylindrical roller having an inner and an outer surface;
 wherein said donor substrate is an optically transparent first rigid or flexible material sheet having an energy absorbing film interposed between said donor substrate and said small molecule organic semiconductor layer;   wherein said acceptor substrate is a second rigid or flexible material sheet,   wherein said first and said second material sheets are passed simultaneously between said hollow cylindrical roller and a second roller, said rollers being in contact with one another along their longitudinal axes to permit said sublimation and said deposition of said small organic molecule from said first material sheet to said second material sheet.   
     
     
         12 . The system of  claim 1 , wherein said small molecule organic semiconductor layer comprises a polycyclic aromatic compound, said polycyclic aromatic compound represented generally by the formula: 
       
         
           
           
               
               
           
         
       
       wherein each R 3 , R 4 , R 5  and R 6  is independently selected from the group consisting of: hydrogen, alkyl of 1-12 carbon atoms, aryl, substituted aryl, a group wherein R 3  and R 4  together form one or more fused benzo rings and a group wherein R 5  and R 6  together form one or more fused benzo rings; and
 wherein n is at least 1. 
 
     
     
         13 . The system of  claim 12 , wherein said polycyclic aromatic compound is pentacene. 
     
     
         14 . The system of  claim 1 , wherein said precursor is a precursor to a polycyclic aromatic compound;
 wherein said precursor to a polycyclic aromatic compound is a Diels-Alder adduct of a polycyclic aromatic compound with a dienophile, wherein said polycyclic aromatic compound is selected from the group consisting of: oligothiophene, perylene, benzo[ghi]perylene, coronene and polyacene; and wherein said dienophile is represented by the formula:
   R 1 —X═Y—R 2    
   wherein each X and Y is independently selected from the group consisting of: N and CR 7 ;   wherein R 1 —X═ is selected from the group consisting of: O, S, SO and SO 2 ; and   wherein each R 1 , R 2  and R 7  is independently selected from the group consisting of: hydrogen, alkyl of 1-12 carbon atoms, aryl, substituted aryl, aralkyl, alkoxycarbonyl, aryloxycarbonyl, acyl and a group R, wherein R is selected from the group consisting of: hydrogen, alkyl of 1-12 carbon atoms, alkoxy, acyl, aryl, aralkyl, chloroalkyl, fluoroalkyl and substituted aryl having a substituent selected from the group consisting of: —F, —Cl, —Br, —NO 2 , —CO 2 R, —PO 3 H, —SO 3 H, trialkylsilyl and acyl; wherein said acyl is represented by the formula: R 8 CO— wherein R 8  is selected from the group consisting of: hydrogen, alkyl of 1-12 carbon atoms, aryl, substituted aryl, aralkyl and fluoroalkyl;   with the proviso that at least one of X and Y is a hetero atom selected from the group consisting of: N, O and S.