The normal OLED lighting manufacturing methods (also known as organic EL lighting) are vapor deposition and coating method. Furthermore, even using coating method, there is still one type of operation that using similar materials and structures as vapor deposition. Another operation use materials and structures that typical for coating method. Different LED enterprises may choose different manufacturing process. KONICA MINOLTA ADVANCED LAYERS applied the former, while Sumitomo Chemical chose the latter.
According to related reports of KONICA MINOLTA ADVANCED LAYERS, they have obtained great progress in recent researches and developments. “We have dramatically improved the yield of emitting layers, which had really low rate of production. They have much similar qualities with vapor deposition products. ” suggested by Tsuji Takatoshi, the general manager of OLED marketing center of this company. In the meanwhile, by using the large radiation-ray facility “Spring-8”, research groups of KONICA MINOLTA ADVANCED LAYERS analyzed the detailed internal structure, finding reasons for solidifications. Sumitomo Chemical applied a totally different OLED lighting manufacturing solution: a polymer material with multiple functions. They intend to head for the direction of simplified element structures.
There are some other makers (Mitsubishi Chemical and Pioneer) developed other methods that focused on color confusion, producing EL lighting components with display functions. Similar to display technology, this method can realize full color display (on one panel) via coating red (R), green (G) and blue (B) phosphor powders on light-emitting layers.
Showa Denko also developed their new OLED lighting manufacturing technology: using a completely different component structure – “COLED (cavity organic light emitting diodes), which is developed with SRI International, USA.”. i.e. do uneven process on the surface of glass bases, and add material depositions. Expect for a target of 150lm/W by 2015, Showa Denko did not reveal any detailed information about their studies. The current luminous efficiency of organic EL lighting components is around 30lm/W. Even so, Showa Denko still have full confidence on the development of COLED. “In the competitions with other large LED Panel Light enterprises, COLED is a powerful weapon. It is not surprise to hear that products from other companies have reached up to 128lm/W. We believe that COLED will have better performance in luminous efficiency.” said Suzuki Guangzhi, director of Electric Research and Development Section of Showa Denko.