Direct mask-free patterning of molecular organic semiconductors using organic vapor jet printing

We demonstrate the solvent-free, high-resolution direct printing of molecular organic semiconductors for use in low cost optoelectronic applications. In this method, called organic vapor jet printing, hot inert carrier gas picks up the molecular organic vapor and expands it through a microscopic nozzle, resulting in physisorption of the molecules onto a cooled substrate. Pattern resolution and printing speed are determined by the nozzle shape, nozzle-to-substrate distance, downstream pressure, and molecular mass of the carrier gas. Quantitative models are developed using a combination of scaling analysis, direct simulation Monte Carlo modeling, and printing experiments. Pattern resolutions of up to 1000dpi and local deposition rates exceeding 2300A∕s are achieved. Pentacene channel thin film transistors are printed at a local deposition rate of 700A∕s at both low and atmospheric pressures, resulting in a field-effect mobility of 0.25cm2∕Vs and a current on/off ratio of 7×105 for devices grown at a backgro...

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