Display panel, display device and manufacturing method thereof

Abstract

The present invention provides a display panel, a display device and a manufacturing method thereof. The display panel includes: a substrate; a main display area, which is arranged on the substrate and has a first supporting structure and a second supporting structure, wherein the height of the first supporting structure is greater than the height of the second supporting structure; a first display area, which is arranged on the substrate and is adjacent to the main display area in a first direction; the display panel can be applied to a first display device or a second display device respectively, wherein the first display device has a first display area, and the second display device has a second display area, and the first display area is different from the second display area, wherein the first display area includes the main display area and the first display area, and the second display area includes the main display area but does not include the first display area; the first display area has a second supporting structure but does not have a first supporting structure.

Description

Technical Field

[0001] The present invention relates to a display panel and a display device using the same, and in particular to a display panel capable of realizing mask sharing, a display device and a manufacturing method thereof, and a mask plate used in the manufacturing process. Background Art

[0002] With the development of technology, display devices are widely used in many electronic products, such as mobile phones, tablet computers, watches, cars, etc.

[0003] For display devices of the same series, their size and resolution are the same, and the only difference is the size of the opening (bangs), such as IPHONE 12 and IPHONE 13. When manufacturing display devices of the same series with different openings, different masks need to be developed accordingly, resulting in increased costs.

[0004] In addition, in different display devices, the opening area can be used as a display area or covered by a light shielding layer, resulting in a height difference between the display area and the opening area, resulting in different degrees of brightness unevenness (mura).

[0005] Therefore, how to provide a display panel and a display device that can share more mask layers, reduce production costs, increase production efficiency, and improve display quality is one of the problems that need to be solved. Summary of the invention

[0006] Embodiments of the present invention provide a display panel, a display device, and a method for manufacturing the same, as well as a mask plate used in the manufacturing process, which can share the mask plate on one side of a color filter substrate (i.e., the color filter substrate side, referred to as the CF side), thereby reducing production costs and improving production efficiency. It can also effectively avoid the occurrence of uneven brightness and improve display quality.

[0007] A display panel according to one embodiment of the present invention comprises a substrate; a main display area arranged on the substrate and having a first supporting structure and a second supporting structure, the height of the first supporting structure being greater than the height of the second supporting structure; a first display area arranged on the substrate and adjacent to the main display area in a first direction; the display panel can be applied to a first display device or a second display device respectively, the first display device having a first display area, the second display device having a second display area, and the first display area is different from the second display area, the first display area includes the main display area and the first display area, the second display area includes the main display area and does not include the first display area; wherein the first display area has the second supporting structure and does not have the first supporting structure.

[0008] The above-mentioned display panel, wherein the display panel also includes a secondary display area, which is arranged on the substrate and is adjacent to the main display area in a second direction; the first direction intersects with the second direction, the second display area includes the secondary display area, and the first display area does not include the secondary display area, and the secondary display area has a first supporting structure and a second supporting structure.

[0009] The above-mentioned display panel, wherein the display panel further has an opening area, the opening area is adjacent to the first display area and the second display area, and the opening area has a third supporting structure.

[0010] In the above display panel, the first non-display area has a first width W1 in the first direction, the first sub-display area has a second width W2 in the first direction, and 0.1*W1≤W2≤0.2*W1.

[0011] The above display panel is characterized in that the second width W2 of the first display area is ≤1000um.

[0012] The above-mentioned display panel is characterized in that the secondary display area has a first length L1 in the second direction, and the first length L1 is much larger than the second width W2.

[0013] In the above-mentioned display panel, the first display device and the second display device have the same size and / or the same resolution.

[0014] A display device according to one embodiment of the present invention comprises: a display panel as described above; the first display device has a first shading element, and the second display device has a second shading element; wherein the first shading element has a plurality of regularly arranged hollow portions in the first display area, and the second shading element has a plurality of regularly arranged hollow portions in the second display area.

[0015] In the above-mentioned display device, the first shading element covers the first non-display area, and the second shading element covers the second non-display area.

[0016] A method for manufacturing a display panel according to an embodiment of the present invention comprises providing a substrate; forming a first supporting structure and a second supporting structure on the substrate, wherein the height of the first supporting structure is greater than the height of the second supporting structure; the first supporting structure and the second supporting structure are arranged in a main display area; the second supporting structure is arranged in a first display area; the first display area is adjacent to the main display area in a first direction; the display panel can be applied to a first display device or a second display device respectively, the first display device has a first display area, the second display device has a second display area, and the first display area is different from the second display area, the first display area includes the main display area and the first display area, the second display area includes the main display area and does not include the first display area; wherein the first display area does not have the first supporting structure.

[0017] A method for manufacturing a display device according to one embodiment of the present invention comprises: the method for manufacturing a display panel as described above; forming a shading layer on the substrate; wherein the first display device has a first shading element, and the second display device has a second shading element; the first shading element has a plurality of regularly arranged hollow portions in the first display area, and the second shading element has a plurality of regularly arranged hollow portions in the second display area.

[0018] A mask plate according to one embodiment of the present invention is applied to any one of the display panels described above, and the mask plate includes: a main body, the main body having a first area and a second area adjacent to each other, the first area including a first pattern and a second pattern, and the first pattern is different from the second pattern, the first pattern is used to form the first supporting structure, the second pattern is used to form the second supporting structure, and the height of the first supporting structure is greater than the height of the second supporting structure; the second area includes the second pattern and does not include the first pattern, so as to form the second supporting structure in the first display area of ​​the substrate.

[0019] The present invention is described in detail below with reference to the accompanying drawings and specific embodiments, but is not intended to limit the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic structural diagram of a display panel according to an embodiment of the present invention.

[0021] Figure 2 It is a schematic structural diagram of a first display device according to an embodiment of the present invention.

[0022] Figure 3 It is a schematic structural diagram of a second display device according to an embodiment of the present invention.

[0023] Figure 4 yes Figure 2 Schematic diagram of the enlarged area A in the middle.

[0024] Figure 5 yes Figure 3 Schematic diagram of the enlarged area A in the middle.

[0025] Figure 6 yes Figure 4 Schematic diagram of the cross section along the B-B' line.

[0026] Figure 7 yes Figure 5 Schematic diagram of the cross section along the B-B' line.

[0027] Wherein, the reference numerals are:

[0028] 100: Display panel

[0029] 101: Substrate

[0030] 102: Main display area

[0031] 103: Display area for the first time

[0032] 104: Second display area

[0033] 105: Opening

[0034] 106: First non-display area

[0035] 107: Second non-display area

[0036] 200: first display device

[0037] 200': Second display device

[0038] 201: Substrate

[0039] 202: First light shielding layer

[0040] 202': Second light shielding layer

[0041] 203: Color blocking layer

[0042] 204: Flat layer

[0043] AA1: First display area

[0044] AA2: Second display area

[0045] S1: First support structure

[0046] S2: Second support structure DETAILED DESCRIPTION

[0047] The structural principle and working principle of the present invention are described in detail below in conjunction with the accompanying drawings:

[0048] Figure 1 is a schematic structural diagram of a display panel according to an embodiment of the present invention, Figure 2 is a schematic structural diagram of a first display device according to an embodiment of the present invention, Figure 3 FIG. 1 is a schematic diagram of the structure of a second display device according to an embodiment of the present invention. Figure 3 As shown, the display panel 100 of the present invention includes a substrate 101 , a main display area 102 , a first display area 103 , a second display area 104 and an opening 105 .

[0049] Specifically, Figure 1 As shown, in the display panel 100, the main display area 102, the first display area 103, the second display area 104 and the opening 105 are all arranged in the substrate 101. The main display area 102 is provided with a first supporting structure and a second supporting structure (not shown in the figure), and the height of the first supporting structure is greater than the height of the second supporting structure. The first display area 103 is adjacent to the main display area 102 in a first direction, and the first direction is, for example, the vertical direction as shown in the figure, and the second display area 104 is adjacent to the main display area 102 in a second direction, and the second direction is, for example, the horizontal direction as shown in the figure.

[0050] like Figure 2 , Figure 3 As shown, the display panel 100 can be applied to a first display device 200 or a second display device 200', respectively, and the first display device 200 and the second display device 200' have the same size and / or the same resolution. The first display device 200 has a first display area AA1, and the second display device 200' has a second display area AA2, wherein the first display area AA1 is different from the second display area AA2.

[0051] like Figure 1 , Figure 2 As shown, the first display device 200 has a first display area AA1 and a first non-display area 106 (bangs), the first display area AA1 and the first non-display area 106 are arranged correspondingly, and the first display area AA1 is composed of the main display area 102 and the first display area 103. Among them, the first non-display area 106 has a first width W1 in the first direction. The first display area 103 has a second width W2 in the first direction, the second width W2≤1000um, and the first width W1 and the second width W2 must satisfy: 0.1*W1≤W2≤0.2*W1, which can also be said that the second width W2 is smaller in size, and the first width W1 is much larger than the second width W2.

[0052] like Figure 1 , Figure 3 As shown, the second display device 200' has a second display area AA2 and a second non-display area 107 (bangs), the second display area AA2 and the second non-display area 107 are arranged correspondingly, and the second display area AA2 is composed of the main display area 102 and the secondary display area 104. Among them, the secondary display area 104 has a first length L1 in the second direction, and the first length L1 is, for example, about 3500um≤L1≤4000um, which can also be said that the first length L1 is much larger than the second width W2.

[0053] That is, the area where the first display area AA1 overlaps with the second display area AA2 corresponds to the main display area 102 , and the area where the first non-display area 106 overlaps with the second non-display area 107 corresponds to the opening 105 .

[0054] Depend on Figures 1 to 3 It can be seen that the first display area AA1 of the first display device 200 and the second display area AA2 of the second display device 200' have different display areas. Correspondingly, the first non-display area 106 of the first display device 200 and the second non-display area 107 of the second display device 200' are also different, that is, the projection of the first non-display area 106 on the substrate 101 is different from the projection of the second non-display area 107 on the substrate 101.

[0055] For example Figure 2 , Figure 3 As shown, the first non-display area 106 of the first display device 200 can be covered by a first light shielding layer (not shown in the figure), and the second non-display area 107 of the second display device 200' can be covered by a second light shielding layer (not shown in the figure). Correspondingly, the first light shielding layer exposes the first display area AA1, and the second light shielding layer exposes the second display area AA2.

[0056] Combination Figures 1 to 3 As shown, from another perspective, the first light shielding layer used for the first display device 200 covers the opening 105 and the secondary display area 104, and the second light shielding layer used for the second display device 200' covers the opening 105 and the first display area 103. That is, the first display area 103 is used as a display area when used in the first display device 200, and is covered by the second light shielding layer when used in the second display device 200'. The second display area 104 is covered by the first light shielding layer when used in the first display device 200, and is used as a display area when used in the second display device 200'.

[0057] Figure 4 yes Figure 2 The enlarged schematic diagram of area A in the middle, Figure 5yes Figure 3 Enlarged schematic diagram of area A in the middle. Figure 2-Figure 5 As shown, in the first display device 200 and the second display device 200', the main display area 102 corresponding to the first display area AA1 and the second display area AA2 is provided with both the first support structure S1 and the second support structure S2. The first display area 103 is only provided with the second support structure S2, and the first support structure S1 is not provided. The second display area 104 is provided with the first support structure S1 and the second support structure S2.

[0058] Specifically, Figure 6 yes Figure 4 Schematic diagram of the cross section along the B-B' line, Figure 7 yes Figure 5 Schematic diagram of the cross section along the B-B' line. Figure 1-Figure 7 ,like Figure 6 As shown, a first light shielding layer 202, a color resist layer 203, and a planarization layer 204 are sequentially arranged on a substrate 101 of the first display device 200. In the first display device 200, the first display area 103 is used as a display area, the first light shielding layer 202 completely covers the first non-display area 106, and a plurality of hollow structures (grooves) are arranged in the first display area AA1 to expose the color resist layer 203. The structures and thicknesses of the first light shielding layer 202, the color resist layer 203, and the planarization layer 204 in the first display area 103 are the same as those in the main display area 102. Therefore, when transitioning from the main display area 102 to the opening 105, there is no obvious height difference between the planarization layer 204 in the main display area 102 and the first display area 103 (and between the first display area 103 and the opening 105).

[0059] like Figure 7 As shown, a second light shielding layer 202', a color resist layer 203 and a planarization layer 204 are sequentially disposed on the substrate 101 of the second display device 200'. In the second display device 200', the second light shielding layer 202' completely covers the second non-display area 107, the first display area 103 is covered by the second light shielding layer 202', and the second light shielding layer 202' is provided with a plurality of hollow structures (grooves) in the second display area AA2 to expose the color resist layer 203.

[0060] Since the second light shielding layer 202' located in the first display area 103 does not need to expose the color resist layer 203, no hollow structure is formed. In the process of forming the second light shielding layer 202', the material flow characteristics are followed, and its thickness (for example, about 1.3um) is greater than the thickness of the second light shielding layer 202' with a hollow structure located in the main display area 102 (for example, about 1um). The thickness difference between the two is usually about 0.3um. The color resist layer 203 located in the first display area 103 and the color resist layer 203 located in the main display area 102 usually have the same thickness, for example, 2um. For the planarization layer 204, in accordance with the topography of the main display area 102 and the first display area 103 and the material flow characteristics, the thickness in the first display area 103 (for example, about 1.5um) is smaller than the thickness of the planarization layer 204 located in the main display area 102 (for example, about 2.5um). The planarization layer 204 on the main display area 102 and the first display area 103 may not eventually present a whole plane without height difference. A height difference CG is formed between the lower surface of the planarization layer 204 in the first display area 103 and the lower surface of the planarization layer 204 in the main display area 102. The height difference CG is approximately the difference between the sum of the thickness of the second light shielding layer 202', the color resist layer 203 and the planarization layer 204 in the first display area 103 (1.3+2+1.5) and the sum of the thickness of the color resist layer 203 and the planarization layer 204 in the main display area 102 (2+2.5), that is, the height difference CG is approximately 0.3um. Therefore, when transitioning from the main display area 102 to the opening 105, there is a height difference CG between the planarization layer 204 in the main display area 102 of the second display device 200' and the first display area 103.

[0061] Since the height of the first support structure S1 is greater than the height of the second support structure S2, at this time, if the first support structure S1 is also provided in the first display area 103 according to the structure in the main display area 102, then in the process of forming the display device 200', the planarization layer 204 in the first display area 103 is supported by the higher first support structure S1, and at the same time, the second width W2 of the first display area 103 in the first direction is smaller, so when the main display area 102 transitions to the opening 105, since the transition area where the first display area 103 is located is small in size and there is a significant height difference between the transition area and the main display area 102 (and the opening 105), a drastic height difference change occurs in a small area, causing the substrate 101 to deform, which will cause the main display area 102 near the first display area 103 to have uneven brightness. In the second display device 200' of the present invention, there is a height difference between the planarization layer 204 of the main display area 102 and the first display area 103, based on which, the higher first support structure S1 is not provided in the first display area 103. When the main display area 102 transitions to the opening 105, there will be no large height difference between the transition zone where the first display area 103 is located and the main display area 102 (and the opening 105), so there will be no drastic height difference change in the transition zone, avoiding uneven brightness.

[0062] For the second display area 104, since its length L1 is much larger than the second width W2, in other words, the second display area 104 has a sufficiently large length dimension. Therefore, when transitioning from the main display area 102 to the opening 105, no drastic change in height difference will occur in a small area. The second display area 104 can adopt the same support structure as the main display area 102, including both the first support structure S1 and the second support structure S2. Of course, it can also adopt the same support structure as the first display area 103, that is, only including the second support structure S2, but the present invention is not limited to this.

[0063] Based on the above, the present invention only has a second supporting structure S2 in the first display area 103, and no first supporting structure S1 is provided. This allows the display panel 100 to share the mask template of the supporting structure when used as the first display device 200 or the second display device 200', and also avoids the occurrence of uneven brightness.

[0064] The opening 105 is also provided with a supporting structure, such as a third supporting structure (not marked in the figure). The third supporting structure can be the same supporting structure as the main display area (such as Figure 4 and Figure 5 As shown), the same supporting structure as the first display area may also be used, or other supporting structures, etc. The present invention is not limited thereto.

[0065] The above takes the application to two display devices as an example. For the application to multiple display devices, the overlapping area of ​​the display areas of the multiple display devices corresponds to the main display area, and the display areas other than the main display area in the display area of ​​each display device are defined as the secondary display area. The overlapping area of ​​the non-display areas of the multiple display devices corresponds to the opening, and the non-display area of ​​each display device is composed of the opening and the secondary display areas of other display devices.

[0066] Of course, the specific structure of the display panel, the display device and other film layer structures therebetween will not be described in detail here.

[0067] The manufacturing method of the display panel of the present invention is combined with Figures 1 to 7 As shown, the manufacturing method of the display panel 100 includes the following steps:

[0068] First, a substrate 101 is provided.

[0069] Next, a first support structure S1 and a second support structure S2 are formed on the substrate 101, and the height of the first support structure S1 is greater than that of the second support structure S2. The first support structure S1 and the second support structure S2 are disposed in the main display area 102, and the second support structure S2 is disposed in the first display area 103, and the first display area 103 is adjacent to the main display area 102 in the first direction. The display panel 100 can be applied to a first display device 200 or a second display device 200', respectively. The first display device 200 has a first display area AA1, and the second display device 200' has a second display area AA2, and the first display area AA1 is different from the second display area AA2, the first display area AA1 includes the main display area 102 and the first display area 103, and the second display area AA2 includes the main display area 102 and the second display area 104, and does not include the first display area 103. The first display area 103 does not have the first support structure S1.

[0070] For the manufacturing method of the display device of the present invention, Figures 1 to 7 As shown, after the manufacturing method of the display panel 100 is used, the following steps are further included:

[0071] A light shielding layer is formed on the substrate 101. The first display device 200 has a first light shielding layer 202, and the second display device 200' has a second light shielding layer 202'; the first light shielding layer 202 covers the first non-display area 106 and exposes the first display area AA1, and the second light shielding layer 202' covers the second non-display area 107 and exposes the second display area AA2.

[0072] From another perspective, the first light shielding layer 202 covers the opening 105 and the secondary display area 104, and the second light shielding layer 202' covers the opening 105 and the primary display area 103. Moreover, the first light shielding layer 202 has a plurality of regularly arranged hollow portions in the first display area AA1, and the second light shielding element 202' has a plurality of regularly arranged hollow portions in the second display area AA2.

[0073] Of course, the specific structures of the display panel and the display device and the manufacturing methods of other film layer structures will not be described in detail here.

[0074] In the manufacturing process of the display panel 100, a mask plate is required to form the support structure. The present invention also provides a mask plate for manufacturing the display panel. Figure 1-Figure 7 As shown, the mask of the present invention comprises:

[0075] A main body, wherein the main body has a first area and a second area adjacent to each other, the first area includes a first pattern and a second pattern, and the first pattern is different from the second pattern, the first pattern is used to form the first supporting structure S1, and the second pattern is used to form the second supporting structure S2, and the height of the first supporting structure S1 is greater than the height of the second supporting structure S2;

[0076] The second region includes the second pattern but does not include the first pattern, so as to form a second supporting structure S2 in the first display region 103 of the substrate 101 .

[0077] According to an embodiment of the present invention, for different display devices of the same size and the same resolution, the same mask can be used to form a support structure in the main display area and the corresponding secondary display area. The area where the display areas of the multiple display devices overlap corresponds to the main display area. In the display area of ​​each display device, the other display areas except the main display area are defined as secondary display areas. The area where the non-display areas of the multiple display devices overlap corresponds to the opening. The non-display area of ​​each display device can be composed of the opening and the secondary display area of ​​other display devices. Thus, different display devices can be formed by setting corresponding shading layers. The number of mask layers required between different types of display devices is reduced, production costs are saved, and production efficiency is improved. It can also avoid the occurrence of uneven brightness and improve display quality.

[0078] Of course, the present invention may have many other embodiments. Without departing from the spirit and essence of the present invention, those skilled in the art may make various corresponding changes and modifications based on the present invention, but these corresponding changes and modifications should all fall within the scope of protection of the claims attached to the present invention.

Claims

1. A display panel, characterized in that: include: a substrate; a main display area, disposed on the substrate, and having a first supporting structure and a second supporting structure, wherein the height of the first supporting structure is greater than the height of the second supporting structure; A first display area, disposed on the substrate and adjacent to the main display area in a first direction; The display panel can be applied to a first display device or a second display device, respectively. The first display device has a first display area, and the second display device has a second display area. The first display area is different from the second display area. The first display area includes the main display area and the first secondary display area, and the second display area includes the main display area but does not include the first secondary display area. The display panel further comprises an opening area, the opening area is adjacent to the first display area, and the opening area comprises a third supporting structure; The opening area has a first width W1 in the first direction, the first display area has a second width W2 in the first direction, and 0.1*W1≤W2≤0.2*W1; In the first display device, the first display area is used as a display area; In the second display device, the first display area is used as a non-display area, and there is a height difference between the first display area and the lower surface of the main display area; The first display area has a second supporting structure but does not have a first supporting structure, so as to avoid deformation of the substrate caused by the height difference when the first display area is used as a non-display area.

2. The display panel according to claim 1, wherein: The display panel also includes a secondary display area, which is arranged on the substrate and is adjacent to the main display area in a second direction; the first direction intersects with the second direction, the second display area includes the secondary display area, and the first display area does not include the secondary display area, and the secondary display area has a first supporting structure and a second supporting structure.

3. The display panel according to claim 2, wherein: The opening area is adjacent to the secondary display area.

4. The display panel according to claim 3, wherein: The display panel includes a first non-display area, the first non-display area includes the opening area and the secondary display area, and the secondary display area has the same width as the opening area in the first direction.

5. The display panel according to claim 4, wherein: The second width W2 of the first display area is ≤1000um.

6. The display panel according to claim 4, wherein: The second display area has a first length L1 in the second direction, and the first length L1 is much greater than the second width W2.

7. The display panel according to claim 1, wherein: The first display device and the second display device have the same size and / or the same resolution.

8. A display device, characterized in that: include: A display panel as claimed in any one of claims 1 to 7; The first display device has a first shading element, and the second display device has a second shading element; wherein, The first light shielding element has a plurality of regularly arranged hollow portions in the first display area, and the second light shielding element has a plurality of regularly arranged hollow portions in the second display area.

9. The display device according to claim 8, wherein: The display panel includes a first non-display area and a second non-display area, the first non-display area includes the opening area and the second display area, the second display area has the same width as the opening area in the first direction; the second non-display area includes the opening area and the first display area; The first light shielding element covers the first non-display area, and the second light shielding element covers the second non-display area.

10. A method for manufacturing a display panel, characterized in that: include: providing a substrate; forming a first supporting structure, a second supporting structure and a third supporting structure on the substrate, wherein the height of the first supporting structure is greater than the height of the second supporting structure; The first supporting structure and the second supporting structure are arranged in a main display area; the second supporting structure is arranged in a primary display area; and the third supporting structure is arranged in an opening area; The first display area is adjacent to the main display area in a first direction; the display panel can be applied to a first display device or a second display device respectively, the first display device has a first display area, the second display device has a second display area, and the first display area is different from the second display area, the first display area includes the main display area and the first display area, the second display area includes the main display area and does not include the first display area; the opening area is adjacent to the first display area; The opening area has a first width W1 in the first direction, the first display area has a second width W2 in the first direction, and 0.1*W1≤W2≤0.2*W1; In the first display device, the first display area is used as a display area; In the second display device, the first display area is used as a non-display area, and there is a height difference between the first display area and the lower surface of the main display area; The first display area does not have the first supporting structure, so as to avoid deformation of the substrate caused by the height difference when the first display area is used as a non-display area.

11. A method for manufacturing a display device, characterized in that: include: The method for manufacturing a display panel as claimed in claim 10; A shading layer is formed on the substrate; wherein the first display device has a first shading element, and the second display device has a second shading element; the first shading element has a plurality of regularly arranged hollow portions in the first display area, and the second shading element has a plurality of regularly arranged hollow portions in the second display area.

12. A mask plate, applied to any display panel according to claim 1-7, characterized in that: The mask comprises: A main body, wherein the main body has a first area and a second area adjacent to each other, the first area includes a first pattern and a second pattern, and the first pattern is different from the second pattern, the first pattern is used to form the first supporting structure, the second pattern is used to form the second supporting structure, and the height of the first supporting structure is greater than the height of the second supporting structure; The second area includes a second pattern but does not include a first pattern, so as to form the second supporting structure in the first display area of ​​the substrate.

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