Display panel and preparation method thereof

Abstract

The embodiment of the invention discloses a display panel and a preparation method thereof, and the method comprises the following steps: obtaining a real-time image in an opening area, recognizing an abnormal projection according to the comparison of the real-time image and a standard image, and obtaining the position information of the abnormal projection; the driving substrate is turned over, so that the opening faces downwards; the abnormal protrusions are removed according to the position information, so that dug holes are formed in the areas, corresponding to the abnormal protrusions, of the anodes; the driving substrate is turned over again, so that the opening faces upwards; and filling the dug hole with a repairing material. According to the display panel and the preparation method thereof, the abnormal protrusions are removed after the driving substrate is turned over, the risk that the removed abnormal protrusions are attached to the driving substrate is reduced, and meanwhile the effect of improving the poor dark spots is achieved in the mode that the abnormal protrusions are excessively removed; and then the dug hole is filled with a repairing material, so that the surface flatness of the anode is improved.

Description

Technical Field

[0001] The present application relates to the field of display technology, and in particular to a display panel and a method for preparing the same. Background Art

[0002] One of the factors that has the greatest impact on the yield of OLED products is the large number of dark spots, which makes it difficult to meet customer specifications. The reason for the high incidence of dark spots is mostly related to tiny foreign matter on the anode of OLED devices, metal material precipitation protrusions, and micro-residues of the pixel definition layer. The current mainstream approach is to use technical means such as aging tests to identify and eliminate dark spots, but the essence of this solution is to reduce the impact range of dark spots to make them difficult for the human eye to identify at a long distance, and it does not completely eliminate dark spots from the root.

[0003] In the process of research and practice of the prior art, the inventors of this application found that the types of dark spots mainly include the following three types: type one dark spot is caused by the bulge caused by the precipitation of metal on the anode, which causes the cathode and the anode to short-circuit and produce dark spots; type two dark spot is caused by foreign matter under the anode causing the anode film to bulge, which causes the cathode and the anode to short-circuit and produce dark spots; type three dark spot is caused by the material residue or micro-residue of the pixel definition layer, which causes the uneven spreading of the ink in the organic light-emitting layer, causing the cathode and the anode to short-circuit and produce dark spots. Summary of the invention

[0004] The embodiments of the present application provide a display panel and a method for manufacturing the same, which can improve the effect of poor dark spots.

[0005] The present invention provides a method for manufacturing a display panel, which comprises the following steps:

[0006] A driving substrate is provided, the driving substrate comprising a planar layer, an anode and a pixel definition layer, the anode is arranged on the planar layer, the pixel definition layer is arranged on the anode, a plurality of openings are opened on the pixel definition layer, and one of the openings correspondingly exposes one of the anodes;

[0007] Acquire a real-time image in the opening area, identify the abnormal protrusion and acquire position information of the abnormal protrusion based on the comparison between the real-time image and the standard image;

[0008] Turning over the driving substrate so that the opening faces downward;

[0009] According to the position information, the abnormal protrusion is removed so that the anode forms a hole corresponding to the area of ​​the abnormal protrusion;

[0010] Turning over the driving substrate again so that the opening faces upward;

[0011] Filling the excavated hole with a patching material;

[0012] A light emitting layer and a cathode are sequentially formed on the anode.

[0013] Optionally, in some embodiments of the present application, identifying an abnormal protrusion and obtaining position information of the abnormal protrusion according to the comparison between the real-time image and the standard image includes the following steps:

[0014] According to the comparison between the real-time image and the standard image, determining whether the gray value of the local area of ​​the real-time image is greater than the standard gray value, and if so, determining that there is an abnormal protrusion;

[0015] According to the real-time image, the position information and contour information of the abnormal protrusion are obtained.

[0016] Optionally, in some embodiments of the present application, after determining that there is an abnormal protrusion, the following steps are further included:

[0017] Acquiring a contour line of the abnormal protrusion according to the contour information of the abnormal protrusion;

[0018] Based on the contour line, obtaining a difference between a grayscale value of a first area and a grayscale value of a second area, wherein the first area is an area formed by extending the contour line outward by a first distance, and the first area is located outside the contour line, and the second area is an area formed by extending the contour line inward by the first distance, and the second area is located inside the contour line;

[0019] Determine whether the difference between the grayscale value of the first area and the grayscale value of the second area is within a set range;

[0020] If the difference is within the set range, it is determined that the abnormal protrusion is formed below the surface of the anode close to the flat layer, and the abnormal protrusion is a first type of abnormal protrusion.

[0021] Optionally, in some embodiments of the present application, removing the abnormal protrusion so that the anode forms a hole corresponding to the area of ​​the abnormal protrusion comprises the following steps:

[0022] According to the position information and the contour information of the abnormal protrusion, the abnormal protrusion is removed to form a hole, and the depth of the hole is greater than or equal to the thickness of the anode.

[0023] Optionally, in some embodiments of the present application, filling the excavated hole with a repair material comprises the following steps:

[0024] Acquiring film layer information of the anode, wherein the film layer information includes the number of film layers, material information of each film layer, and thickness information of each film layer;

[0025] If the number of the membrane layer is one layer, the same material as that of the anode is selected as the repair material to fill the hole;

[0026] If the number of the membrane layers is at least two, the same material as the thickest membrane layer in the anode is selected as the repair material to fill the hole, or, according to the order of the membrane layers, the same material as the corresponding membrane layers in the anode is selected in turn as the repair material to repair the hole.

[0027] Optionally, in some embodiments of the present application, after determining whether the difference between the grayscale value of the first area and the grayscale value of the second area is within a set range, the following steps are further included:

[0028] If the difference is not within the set range, it is determined that the abnormal protrusion is formed on the surface of the anode away from the flat layer, and the abnormal protrusion is a second type of abnormal protrusion.

[0029] Optionally, in some embodiments of the present application, removing the abnormal protrusion so that the anode forms a hole corresponding to the area of ​​the abnormal protrusion comprises the following steps:

[0030] According to the position information and the contour information of the second type of abnormal protrusions, the abnormal protrusions are removed to form a hole, wherein the depth of the hole is less than the thickness of the anode;

[0031] Filling the excavated hole with a repair material also includes the following steps:

[0032] Acquiring film layer information of the anode, wherein the film layer information includes the number of film layers and material information of each film layer;

[0033] The same material as the film layer in the anode that is in direct contact with the second type of abnormal protrusion is selected as the repair material to fill the hole.

[0034] Optionally, in some embodiments of the present application, removing the abnormal protrusion to form a hole further includes the following steps:

[0035] According to the position information and the contour information of the abnormal protrusion, the contour line information of the hole is obtained and a first contour line trajectory of the hole is generated, wherein the first contour line trajectory of the hole is formed by extending the contour line of the abnormal protrusion outward by a second distance, and the second distance is between 0.4 micrometers and 1 micrometer;

[0036] determining whether the first contour line trajectory is within the inner contour of the opening;

[0037] If the first contour line trajectory is within the inner contour of the opening, the abnormal protrusion is removed according to the first contour line trajectory to form the excavated hole.

[0038] Optionally, in some embodiments of the present application, after determining whether the first contour line trajectory is within the inner contour of the opening, the following steps are further included:

[0039] If a portion of the first contour line track exceeds the inner contour of the opening, removing the portion of the first contour line track exceeding the inner contour of the opening to generate a second contour line track;

[0040] According to the second contour line trajectory, the abnormal protrusion is removed to form the hole.

[0041] Optionally, in some embodiments of the present application, the repair material is filled in the hole by inkjet printing, and the abnormal protrusion is removed by laser.

[0042] Accordingly, an embodiment of the present application further provides a display panel, which includes:

[0043] A driving substrate, comprising a planar layer, an anode and a pixel definition layer, wherein the anode is arranged on the planar layer, the pixel definition layer is arranged on the anode, a plurality of openings are provided on the pixel definition layer, one opening correspondingly exposes one anode, a hole is provided on the anode, the hole is filled with a repair material, and the repair material is at least partially the same as the material of the anode;

[0044] a light-emitting layer covering the anode and the repair material;

[0045] A cathode covers the light-emitting layer.

[0046] Optionally, in some embodiments of the present application, the anode is a single film layer, and the repair material is consistent with the material of the anode;

[0047] Alternatively, the depth of the hole is greater than or equal to the thickness of the anode, the anode is formed by stacking at least two first film layers, the repair material is formed by stacking at least two second film layers, and the first film layer and the second film layer arranged in the same layer are made of the same material;

[0048] Alternatively, the depth of the hole is greater than or equal to the thickness of the anode, the anode is formed by stacking at least two first film layers, and the repair material is the same as the material of the thickest film layer in the anode;

[0049] Alternatively, the depth of the hole is smaller than the thickness of the anode, the anode is formed by stacking at least two film layers, and the repair material is the same as the material of the film layer in the anode that is farthest from the flat layer.

[0050] The display panel and preparation method of the embodiment of the present application remove the abnormal protrusions after flipping the driving substrate, so that the removed abnormal protrusions fall due to gravity, reducing the risk of the removed abnormal protrusions adhering to the driving substrate. At the same time, holes are left based on the removal of the abnormal protrusions to excessively remove the abnormal protrusions, thereby reducing the risk of short circuits between the anode and the cathode, thereby improving the effect of dark spot defects; then, a repair material is used to fill the holes left after removing the abnormal protrusions, thereby improving the surface flatness of the anode and thus improving the uniformity of the thickness of the light-emitting layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Figure 1 is a schematic diagram of a process for preparing a display panel provided in an embodiment of the present application;

[0052] Figure 2 is a schematic diagram of step B1 in the method for preparing a display panel provided in an embodiment of the present application;

[0053] Figure 3 is a schematic diagram of step B3 in the method for preparing a display panel provided in an embodiment of the present application;

[0054] Figure 4 is a schematic diagram of step B4 in the method for preparing a display panel provided in an embodiment of the present application;

[0055] Figure 5 is a schematic diagram of step B5 in the method for preparing a display panel provided in an embodiment of the present application;

[0056] Figure 6 is a schematic diagram of step B6 in the method for preparing a display panel provided in an embodiment of the present application;

[0057] Figure 7 is another schematic diagram of step B6 in the method for preparing a display panel provided in an embodiment of the present application;

[0058] Figure 8 is another schematic diagram of step B6 in the method for preparing a display panel provided in an embodiment of the present application;

[0059] Fig. 9 is a schematic diagram of step B7 in the method for preparing a display panel provided in an embodiment of the present application;

[0060] Fig.10 is a structural schematic diagram of a display panel provided in an embodiment of the present application;

[0061] Fig.11 is another structural schematic diagram of a display panel provided in an embodiment of the present application;

[0062] Fig.12 This is another structural schematic diagram of the display panel provided in the embodiment of the present application. DETAILED DESCRIPTION

[0063] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present application. In addition, it should be understood that the specific implementation methods described herein are only used to illustrate and explain the present application, and are not used to limit the present application. In the present application, the various embodiments can be combined with each other but will not be repeated one by one, and in the absence of contrary instructions, the directional words used, such as "upper" and "lower", usually refer to the upper and lower parts of the device in actual use or working state, specifically the drawing direction in the drawings; while "inside" and "outside" refer to the outline of the device; the terms "first", "second", "third", etc. are used only as markings, and no numerical requirements are imposed or order is established.

[0064] The embodiments of the present application provide a display panel and a method for manufacturing the same, which are described in detail below. It should be noted that the description order of the following embodiments is not intended to limit the preferred order of the embodiments.

[0065] The present invention provides a method for manufacturing a display panel, which comprises the following steps:

[0066] A driving substrate is provided. The driving substrate comprises a planar layer, an anode and a pixel definition layer. The anode is arranged on the planar layer. The pixel definition layer is arranged on the anode. A plurality of openings are opened on the pixel definition layer. One of the openings exposes one of the anodes.

[0067] A real-time image in the opening area is acquired, and based on the comparison between the real-time image and a standard image, abnormal protrusions are identified and position information of the abnormal protrusions is acquired.

[0068] The driving substrate is turned over so that the opening faces downward.

[0069] According to the position information, the abnormal protrusion is removed so that a hole is formed in the anode corresponding to the area of ​​the abnormal protrusion.

[0070] The driving substrate is turned over again so that the opening faces upward.

[0071] The excavated hole is filled with a patching material.

[0072] A light emitting layer and a cathode are sequentially formed on the anode.

[0073] The display panel and preparation method of the embodiment of the present application remove the abnormal protrusions after flipping the driving substrate, so that the removed abnormal protrusions fall due to gravity, reducing the risk of the removed abnormal protrusions adhering to the driving substrate. At the same time, holes are left based on the removal of the abnormal protrusions to excessively remove the abnormal protrusions, thereby reducing the risk of short circuits between the anode and the cathode, thereby improving the effect of dark spot defects; then, a repair material is used to fill the holes left after removing the abnormal protrusions, thereby improving the surface flatness of the anode and thus improving the uniformity of the thickness of the light-emitting layer.

[0074] Please refer to Figure 1 , Figure 1 Shown is a schematic flow chart of a method for preparing a display panel according to one or more embodiments of the present application.

[0075] Step B1, providing a driving substrate, the driving substrate comprising a planar layer, an anode and a pixel definition layer, the anode is arranged on the planar layer, the pixel definition layer is arranged on the anode, a plurality of openings are opened on the pixel definition layer, and one of the openings correspondingly exposes one of the anodes.

[0076] Step B2, obtaining a real-time image within the opening area, identifying abnormal protrusions and obtaining position information of the abnormal protrusions based on comparison between the real-time image and a standard image.

[0077] Step B3, turning over the driving substrate so that the opening faces downward.

[0078] Step B4, removing the abnormal protrusion according to the position information, so that the anode forms a hole corresponding to the area of ​​the abnormal protrusion.

[0079] Step B5, turning over the drive substrate again so that the opening faces upward.

[0080] Step B6, filling the excavated hole with a repair material.

[0081] Step B7, forming a light-emitting layer and a cathode in sequence on the anode.

[0082] The following describes a method for preparing a display panel according to an embodiment of the present application.

[0083] Please refer to Figure 2 Step B1, providing a driving substrate 11. The driving substrate 11 includes a planar layer 111, an anode 112 and a pixel definition layer 113. The anode 112 is disposed on the planar layer 111, and the pixel definition layer 113 is disposed on the anode 112. The pixel definition layer 113 is provided with a plurality of openings 11a, and one opening 11a correspondingly exposes one anode 112.

[0084] Optionally, the anode 112 includes at least one film layer, for example, the anode 112 is only a single film layer structure, or the anode 112 is formed by stacking two conductive film layers, or the anode 112 is formed by stacking three conductive film layers, or the anode 112 is formed by stacking more than three conductive film layers.

[0085] Optionally, the driving substrate 11 further includes a thin film transistor array layer. The planar layer 111 is disposed on the thin film transistor array layer.

[0086] exist Figure 2 In the embodiment, the anode 112 includes a first conductive film layer y1, a reflective metal film layer y2, and a second conductive film layer y3 stacked in sequence, but the invention is not limited thereto. For example, the anode 112 is a single film layer structure.

[0087] Optionally, the first conductive film y1 and the second conductive film y3 are transparent conductive films, such as metal oxides. The reflective metal film layer y2 can be a metal with reflective properties, such as silver.

[0088] In addition, the opening 11a of the pixel definition layer 113 has an inner contour, which is a contour line formed by the sidewall of the opening 11a overlapping one end of the anode 112. The inner contour of the opening 11a is configured to define the shape and size of the sub-pixel.

[0089] It should be understood that the abnormal protrusions include a first type of abnormal protrusion p1 and a second type of abnormal protrusion p2. The first type of abnormal protrusion p1 is formed below the surface of the anode 112 close to the flat layer 111, such as a protrusion formed by dust particles or residual particles of other materials. The second type of abnormal protrusion p2 is formed on the surface of the anode 112 away from the flat layer 111, such as a protrusion formed by residual materials of the pixel definition layer and / or a protrusion formed by metal precipitation of the anode 112.

[0090] The abnormal protrusions in the driving substrate 11 include at least one of the first abnormal protrusions p1 and the second abnormal protrusions p2. For example, it may include only the first abnormal protrusions p1 or the second abnormal protrusions p2, or it may include both the first abnormal protrusions p1 and the second abnormal protrusions p2.

[0091] exist Figure 2 In the description, the example in which the driving substrate 11 includes both the first type of abnormal protrusions p1 and the second type of abnormal protrusions p2 is taken, but the present invention is not limited thereto. For example, the driving substrate 11 only includes the first type of abnormal protrusions p1 or the second type of abnormal protrusions p2.

[0092] Then proceed to step B2.

[0093] Step B2, obtaining a real-time image in the area of ​​the opening 11a, identifying the abnormal protrusion based on the comparison between the real-time image and the standard image, and obtaining the position information of the abnormal protrusion.

[0094] Optionally, a camera is used to photograph and / or scan the driving substrate 11 to obtain a real-time image of the opening 11a region in the driving substrate 11. For example, an optical inspection device (AOI) may be used to obtain a real-time image.

[0095] Then, the real-time image and the standard image are compared to identify the abnormal protrusion and record the position information corresponding to the abnormal protrusion. This step and the step of obtaining the real-time image can be processed in the optical detection device, or this step can be processed by an additional control device.

[0096] Optionally, in some embodiments of the present application, in step B2, identifying the abnormal protrusion and obtaining the position information of the abnormal protrusion according to the comparison between the real-time image and the standard image includes the following steps:

[0097] Step B21, based on the comparison between the real-time image and the standard image, determine whether the grayscale value of the local area of ​​the real-time image is greater than the standard grayscale value, and if so, determine that there is an abnormal protrusion.

[0098] It can be understood that since the abnormal protrusion is higher than the anode 112, the light reflection brightness of the abnormal protrusion is greater, and the greater the grayscale value of the image, the greater the brightness of the image. Therefore, the abnormal protrusion can be identified by judging the size of the grayscale value of the image.

[0099] It should be understood that the standard gray value is the standard gray value of the anode 112 in a flat state. The setting of the standard gray value depends on factors such as the number of film layers of the anode 112, the thickness of each film layer, the material of each film layer, the brightness of the light source during shooting, the distance from the object during shooting, and the exposure degree during shooting. Therefore, the standard gray value of the anode 112 can be set according to actual conditions.

[0100] Optionally, in some embodiments, a 3D image may be formed by acquiring real-time images of the opening 11 a region at multiple angles, and then the abnormal protrusion protruding from the anode 112 may be accurately identified through the 3D image.

[0101] Then proceed to step B22.

[0102] Step B22, obtaining the position information and contour information of the abnormal protrusion according to the real-time image.

[0103] It is understandable that the position information of the abnormal protrusion includes the center coordinate information of the abnormal protrusion, and the contour information of the abnormal protrusion includes the size and shape information of the contour line and the coordinate information of the contour line. The coordinate information of the contour line is formed by fitting the coordinate information of any point on the contour line.

[0104] Optionally, in some embodiments of the present application, after determining that there is an abnormal protrusion, the following steps may also be included:

[0105] Step B23, obtaining the contour line of the abnormal protrusion according to the contour information of the abnormal protrusion.

[0106] It should be noted that, based on the abnormal protrusion being identified and according to the contour information of the abnormal protrusion, the contour line of the abnormal protrusion in the real-time image is obtained. Then, the process proceeds to step B24.

[0107] Step B24, based on the contour line, obtain the difference between the grayscale value of the first area and the grayscale value of the second area, the first area is a area formed by expanding the contour line outward by a first distance, and the first area is located on the outside of the contour line, and the second area is a area formed by expanding the contour line inward by the first distance, and the second area is located on the inside of the contour line.

[0108] It can be understood that the area within the contour line is an abnormal protrusion, and the area outside the contour line is a local area of ​​the anode 112. In other words, the first area is a local area of ​​the anode 112, and the second area is a peripheral area of ​​the abnormal protrusion.

[0109] Optionally, the first distance may be between 0.1 micrometers and 0.5 micrometers, for example, 0.1 micrometers, 0.2 micrometers, 0.3 micrometers, 0.4 micrometers or 0.5 micrometers.

[0110] In addition, the first distance may also be greater than 0.5 micrometers, such as 0.6 micrometers, 0.7 micrometers, 1 micrometer, etc. The first distance may be selected according to actual conditions.

[0111] However, it should be noted that the difference in grayscale values ​​between the first region and the second region is obtained in order to determine whether the abnormal protrusion belongs to the first type of abnormal protrusion or the second type of abnormal protrusion. Since the first type of abnormal protrusion is formed under the anode 112 and is covered by the anode 112, the boundary contour of the first type of abnormal protrusion p1 is relatively fuzzy; while the second type of abnormal protrusion is formed above the anode 112, the boundary contour of the second type of abnormal protrusion p2 is relatively clear.

[0112] Since the boundary contour is clear, the difference in grayscale values ​​between the inner and outer regions (the first region and the second region) representing the contour line is relatively large. The greater the difference in grayscale values, the clearer the boundary contour is, and the smaller the difference in grayscale values, the more blurred the boundary contour is.

[0113] It can be understood that, since the first region is a local region of the anode 112, the grayscale value of the first region is the average grayscale value of the first region, which can be the above-mentioned standard grayscale value. The grayscale value of the second region is the average grayscale value of the second region.

[0114] Then go to step B25.

[0115] Step B25, determining whether the difference between the grayscale value of the first region and the grayscale value of the second region is within a set range.

[0116] Based on the principle that the greater the difference in grayscale values, the clearer the boundary contour, and the smaller the difference in grayscale values, the more blurred the boundary contour, the setting range can be defined as a smaller value range, or the setting range can be defined as a larger value range. When the difference in grayscale values ​​between the first area and the second area is within the smaller range of the setting range, the abnormal protrusion is judged to be a first-type abnormal protrusion p1; when the difference in grayscale values ​​between the first area and the second area is within the larger range of the setting range, the abnormal protrusion is judged to be a second-type abnormal protrusion p2.

[0117] The embodiment of the present application is described by taking the setting range as a smaller value as an example. The specific value of the setting range can be set according to actual conditions, and the present application does not limit it.

[0118] Then proceed to step B26.

[0119] Step B26, if the difference is within the set range, it is determined that the abnormal protrusion is formed below the surface of the anode 112 close to the flat layer 111, and the abnormal protrusion is the first type of abnormal protrusion p1. If the difference is not within the set range, it is determined that the abnormal protrusion is formed on the surface of the anode 112 away from the flat layer 111, and the abnormal protrusion is the second type of abnormal protrusion p2.

[0120] That is to say, if the difference between the grayscale value of the first region and the grayscale value of the second region is small, for example, less than or equal to 3, then the boundary of the abnormal protrusion is determined to be fuzzy, so it is the first type of abnormal protrusion p1. If the difference between the grayscale value of the first region and the grayscale value of the second region is large, for example, greater than 3, then the boundary of the abnormal protrusion is determined to be clear, so it is the second type of abnormal protrusion p2.

[0121] In addition, in some embodiments, the angle of the camera may be adjusted to obtain multiple real-time images at different angles.

[0122] Since the first type of abnormal protrusion p1 is below the anode 112, the difference in light reflection degree at different angles is small and relatively stable. However, the second type of abnormal protrusion p2 is above the anode 112, so the difference in light reflection degree at different angles is large.

[0123] Therefore, based on the difference in the grayscale values ​​of abnormal protrusions in real-time images at different angles, it is possible to assist in determining whether the abnormal protrusion is a first-type abnormal protrusion p1 or a second-type abnormal protrusion p2. If the difference in the grayscale values ​​of abnormal protrusions in real-time images at multiple angles is within the threshold range, the abnormal protrusion is determined to be the first-type abnormal protrusion p1; if the difference in the grayscale values ​​of abnormal protrusions in real-time images at multiple angles is within the threshold range, the abnormal protrusion is determined to be the second-type abnormal protrusion p2.

[0124] Therefore, if the above two identification methods are used to confirm each other in identifying abnormal protrusions, the accuracy of identifying the first type of abnormal protrusion p1 or the second type of abnormal protrusion p2 can be improved.

[0125] Then proceed to step B3.

[0126] Please refer to Figure 3 , step B3, flip the driving substrate 11 so that the opening 11a faces downward.

[0127] Optionally, the driving substrate 11 is turned over from the front side facing up to the front side facing down, so that the opening 11a faces downward. Such an arrangement allows the abnormal protrusion material separated from the driving substrate 11 to fall due to the gravity effect when the abnormal protrusion is removed, thereby reducing the risk of the discarded abnormal protrusion material reattaching to the driving substrate 11 to form abnormal particles.

[0128] Then proceed to step B4.

[0129] Please refer to Figure 4 , step B4, according to the position information, removing the abnormal protrusion, so that the anode 112 forms a hole g1 corresponding to the area of ​​the abnormal protrusion.

[0130] Optionally, the abnormal protrusion is removed according to the position signal and contour information of the abnormal protrusion, wherein the abnormal protrusion may be removed by laser.

[0131] It is understandable that in the process of removing the abnormal protrusion, in order to remove the abnormal protrusion more comprehensively and thoroughly, an over-removal method is usually adopted. Due to the over-removal, the anode 112 forms a hole g1 corresponding to the area of ​​the abnormal protrusion.

[0132] In some embodiments of the present application, step B4, removing the abnormal protrusion to form a hole, further includes the following steps:

[0133] Step B41, based on the position information and contour information of the abnormal protrusion, obtain the contour line information of the hole g1 and generate the first contour line trajectory of the hole g1. The first contour trajectory of the hole g1 is formed based on the contour line of the abnormal protrusion extending outward by a second distance, and the second distance is between 0.4 microns and 1 micron.

[0134] It can be understood that, based on the contour line of the abnormal protrusion, a first contour line trajectory having a range larger than the contour line is formed to excessively remove the abnormal protrusion to improve the cleanliness of removing the abnormal protrusion.

[0135] Among them, the larger the second distance is, the larger the range that needs to be removed is, and the larger the size of the hole g1 is. Therefore, in order to avoid the hole g1 being too large and to ensure the cleanliness of removing abnormal protrusions, the second distance is selected to be between 0.4 microns and 1 micron, for example, it can be 0.4 microns, 0.5 microns, 0.6 microns, 0.7 microns, 0.8 microns, 0.9 microns or 1 micron.

[0136] Then go to step B42.

[0137] Step B42, determining whether the first contour line trajectory is within the inner contour of the opening 11a.

[0138] Step B43: if the first contour line trajectory is within the inner contour of the opening 11a, then according to the first contour line trajectory, the abnormal protrusion is removed to form a hole g1.

[0139] Step B44, if the first contour line trajectory partially exceeds the inner contour of the opening 11a, remove the portion of the first contour line trajectory exceeding the inner contour of the opening 11a to generate a second contour line trajectory; and according to the second contour line trajectory, remove the abnormal protrusion to form a hole g1.

[0140] It should be explained that the contour trajectory of the hole g1 does not exceed the inner contour of the opening 11a, so as to ensure the consistency of the shape and size of the opening 11a, thereby reducing the risk of uneven light emission of sub-pixels.

[0141] Optionally, in some embodiments of the present application, step B4, removing the abnormal protrusion so that the anode 112 forms a hole g1 corresponding to the area of ​​the abnormal protrusion, includes the following steps:

[0142] Step B45 , according to the position information and the contour information of the abnormal protrusion or the first type of abnormal protrusion p1 , remove the abnormal protrusion to form a hole g1 , and the depth of the hole g1 is greater than or equal to the thickness of the anode 112 .

[0143] It is understandable that, according to the position information and contour information of the abnormal protrusion, the area corresponding to the anode 112 corresponding to the abnormal protrusion is directly dug through to completely remove the abnormal protrusion. This method is applicable to the first type of abnormal protrusion p1 and the second type of abnormal protrusion p2, that is, the first type of abnormal protrusion p1 and the second type of abnormal protrusion p2 can be uniformly removed by digging through the anode 112, saving the step of identifying the first type of abnormal protrusion p1 and the second type of abnormal protrusion p2.

[0144] exist Figure 4 In the figure, for the first type of abnormal protrusion p1, the hole g1 is dug through the first conductive film layer y1, the reflective metal film layer y2 and the second conductive film layer y3.

[0145] In some embodiments, Figure 4 As shown, the first type of abnormal protrusion p1 may adopt one hole-digging method, and the second type of abnormal protrusion p2 may adopt another hole-digging method.

[0146] Optionally, the first type of abnormal protrusion p1 adopts the above-mentioned digging method, that is, the area corresponding to the anode 112 corresponding to the first type of abnormal protrusion p1 is dug through to completely remove the first type of abnormal protrusion p1.

[0147] Optionally, in some embodiments of the present application, step B4, removing the abnormal protrusion so that the anode 112 forms a hole corresponding to the area of ​​the abnormal protrusion, also includes the following steps:

[0148] Step B46, according to the position information and the contour information of the second type of abnormal protrusion p2, remove the second type of abnormal protrusion p2 to form a hole g1, and the depth of the hole g1 is less than the thickness of the anode 112.

[0149] It is understandable that there is no order of steps B41 and B42. Since the second type of abnormal protrusion p2 is located on the surface of the anode 112, the depth of the hole g1 can be reduced, thereby reducing the repair cost and improving the repair efficiency in the subsequent steps.

[0150] Optionally, for the second type of abnormal protrusion p2, the depth of the hole g1 is less than the thickness of the second conductive film layer y3. That is, it is sufficient to only dig to the second conductive film layer y3 without digging to the reflective metal film layer y2, thereby reducing the depth of the hole g1.

[0151] In some embodiments, the thickness of the second conductive film layer y3 is greater than that of the first conductive film layer y1, so as to increase the thickness of the second conductive film layer y3 to ensure that for the second type of abnormal protrusion p2, the hole g1 does not touch the reflective metal film layer y2.

[0152] Then go to step B5.

[0153] Please refer to Figure 5 , step B5, flip the driving substrate 11 again so that the opening 11a faces upward.

[0154] It should be explained that the driving substrate 11 is turned over from the front side facing downward to the front side facing upward, so as to facilitate the subsequent repair of the hole g1 and the preparation of the subsequent film layer.

[0155] Then go to step B6.

[0156] Please refer to Figure 6 , step B6, use repair material x1 to fill the hole g1.

[0157] Optionally, the repair material x1 is used to fill the hole g1 by inkjet printing, that is, the repair material x1 is used to fill the hole g1 to improve the flatness of the anode 112 .

[0158] The hole g1 is repaired by inkjet printing. Based on the liquid properties of the raw materials of the repair material x1, it has leveling properties, which can better fill the hole g1 and perform precise repairs on the hole g1.

[0159] Optionally, the surface of the repair material x1 is flush with the surface of the anode 112 .

[0160] It should be understood that due to the accuracy of the equipment, the repair material x1 cannot actually be completely flush with the surface of the anode 112 , so the surface of the repair material x1 is substantially flush with the surface of the anode 112 .

[0161] In some embodiments, the repair material x1 may be a conductive material. The conductive material is used to fill the hole g1 so that the hole g1 area can emit light normally, further improving the effect of dark spots.

[0162] In some embodiments, the repair material x1 is selected from the material of the anode 112 , so that the conductive property and optical property of the repair material x1 are close to or equal to the conductive property and optical property of the anode 112 , thereby improving the light emission uniformity of the sub-pixel.

[0163] In some embodiments of the present application, for the first type of abnormal protrusion p1 or for all types of abnormal protrusions, step B6, using a repair material to fill the hole g1, includes the following steps:

[0164] Step B61, obtaining the film layer information of the anode 112, wherein the film layer information includes the number of film layers, material information of each film layer, and thickness information of each film layer.

[0165] by Figure 2 For example, the film layer information of the anode 112 includes: the number of film layers of the anode 112 is 3, the material of the first conductive film layer y1 is indium tin oxide, the material of the reflective metal film layer y2 is silver, the material of the second conductive film layer y3 is indium tin oxide, the thickness of the first conductive film layer y1 is m1 microns, the thickness of the reflective metal film layer y2 is m2 microns, the thickness of the second conductive film layer y3 is m3 microns, and the thickness of the reflective metal film layer y2 is the largest.

[0166] Step B62, if the number of the film layers is at least two, select the same material as the thickest film layer in the anode 112 as the repair material x1 to fill the hole g1; wherein Figure 6 For example, the same material as the reflective metal film layer y2 is selected as the repair material x1 to fill the hole g1. Alternatively, according to the order of the film layers, the same material as the corresponding film layer in the anode 112 is selected in turn as the repair material x1 to repair the hole g1; Figure 7 As shown, the repair is divided into three times. The first modification is to select the same material as the first conductive film layer y1 as the repair material x1 to fill the portion of the hole g1 located in the first conductive film layer y1; the second modification is to select the same material as the reflective metal film layer y2 as the repair material x1 to fill the portion of the hole g1 located in the reflective metal film layer y2; the third modification is to select the same material as the second conductive film layer y3 as the repair material x1 to fill the portion of the hole g1 located in the second conductive film layer y3.

[0167] If the number of the film layers is one, the same material as the anode 112 is selected as the repair material x1 to fill the hole g1, such as Figure 8 shown.

[0168] In some embodiments of the present application, for the second type of abnormal protrusion p2, step B6, using a repair material to fill the hole g1, includes the following steps:

[0169] Step B61, obtaining the film layer information of the anode 112, wherein the film layer information includes the number of film layers and the material information of each film layer.

[0170] by Figure 2 For example, the film layer information of the anode 112 includes: the number of film layers of the anode 112 is 3, the material of the first conductive film layer y1 is indium tin oxide, the material of the reflective metal film layer y2 is silver, the material of the second conductive film layer y3 is indium tin oxide, the thickness of the first conductive film layer y1 is m1 microns, the thickness of the reflective metal film layer y2 is m2 microns, the thickness of the second conductive film layer y3 is m3 microns, and the thickness of the reflective metal film layer y2 is the largest.

[0171] Step B63, select the same material as the film layer in the anode 112 that directly contacts the second type of abnormal protrusion p2 as the repair material x1 to fill the hole g1. Figure 6 As shown, the material of the second conductive film layer y3 is selected as the repair material x1 to fill the hole g1.

[0172] Then go to step B7.

[0173] Please refer to Fig. 9 , step B7, forming the light-emitting layer 12 and the cathode 13 on the anode 112 in sequence.

[0174] Optionally, the light-emitting layer 12 may be formed by evaporation or inkjet printing, and the cathode 13 may be formed by evaporation or sputtering.

[0175] Accordingly, the embodiment of the present application further provides a display panel 100. It should be noted that the display panel 100 is prepared by the method for preparing a display panel of any one of the above embodiments.

[0176] The display panel 100 includes a driving substrate 11, a light emitting layer 12 and a cathode 13. The driving substrate 11 includes a planar layer 111, an anode 112 and a pixel definition layer 113. The anode 112 is disposed on the planar layer 111. The pixel definition layer 113 is disposed on the anode 112. A plurality of openings 11a are provided on the pixel definition layer 113, and one opening 11a correspondingly exposes one anode 112. A hole g1 is provided on the anode 112, and a repair material x1 is filled in the hole g1. The repair material x1 is at least partially the same as the material of the anode 112.

[0177] The light emitting layer 12 covers the anode 112 and the repair material x1. The cathode 13 covers the light emitting layer 12.

[0178] The display panel 100 of the embodiment of the present application uses a repair material x1 to repair the hole g1 left after removing the abnormal protrusion, thereby improving the dark spot defect and improving the surface flatness of the anode, thereby improving the uniformity of the thickness of the light-emitting layer.

[0179] Optionally, in some embodiments of the present application, the depth of a hole g1 is greater than or equal to the thickness of the anode 112, the anode 112 is formed by stacking at least two first film layers, and the repair material x1 is the same as the material of the film layer with the largest thickness in the anode 112, such as Fig.10 shown.

[0180] Optionally, in some embodiments of the present application, the depth of the other hole g1 is less than the thickness of the anode 112, the anode 112 is formed by stacking at least two film layers, and the repair material x1 is the same as the material of the film layer in the anode 112 that is farthest from the flat layer 111, such as Fig.10 shown.

[0181] Optionally, in some embodiments of the present application, the depth of the hole g1 is greater than or equal to the thickness of the anode 112. The anode 112 is formed by stacking at least two first film layers, and the repair material x1 is formed by stacking at least two second film layers, and the first film layer and the second film layer arranged in the same layer are made of the same material, such as Fig.11 shown.

[0182] Optionally, in some embodiments of the present application, the anode 112 is a single film layer, and the repair material x1 is consistent with the material of the anode 112; wherein the hole g1 may penetrate the anode 112 or may not penetrate the anode 112, such as Fig.12 shown.

[0183] The display panel of the embodiment of the present application leaves a hole g1 after removing the abnormal protrusion, thereby excessively removing the abnormal protrusion and reducing the risk of short circuit between the anode 112 and the cathode 13, thereby improving the dark spot defect; then, the repair material x1 is used to fill the hole g1 left after removing the abnormal protrusion, thereby improving the surface flatness of the anode 112, thereby improving the uniformity of the thickness of the light-emitting layer 12.

[0184] The above is a detailed introduction to a display panel and a preparation method thereof provided in an embodiment of the present application. Specific examples are used herein to illustrate the principles and implementation methods of the present application. The description of the above embodiments is only used to help understand the method of the present application and its core idea. At the same time, for technical personnel in this field, according to the idea of ​​the present application, there will be changes in the specific implementation method and application scope. In summary, the content of this specification should not be understood as a limitation on the present application.

Claims

1. A method for preparing a display panel, characterized in that: The following steps are involved: A driving substrate is provided, the driving substrate comprising a planar layer, an anode and a pixel definition layer, the anode is arranged on the planar layer, the pixel definition layer is arranged on the anode, a plurality of openings are opened on the pixel definition layer, and one of the openings correspondingly exposes one of the anodes; Acquire a real-time image in the opening area, identify the abnormal protrusion and acquire position information of the abnormal protrusion based on the comparison between the real-time image and the standard image; Turning over the driving substrate so that the opening faces downward; According to the position information, the abnormal protrusion is removed so that the anode forms a hole corresponding to the area of ​​the abnormal protrusion; Turning over the driving substrate again so that the opening faces upward; Filling the excavated hole with a patching material; A light emitting layer and a cathode are sequentially formed on the anode.

2. The method for preparing a display panel according to claim 1, characterized in that: According to the comparison between the real-time image and the standard image, the abnormal protrusion is identified and the position information of the abnormal protrusion is obtained, including the following steps: According to the comparison between the real-time image and the standard image, determining whether the gray value of the local area of ​​the real-time image is greater than the standard gray value, and if so, determining that there is an abnormal protrusion; According to the real-time image, the position information and contour information of the abnormal protrusion are obtained.

3. The method for preparing a display panel according to claim 2, characterized in that: After determining that there is an abnormal protrusion, the following steps are also included: Acquiring a contour line of the abnormal protrusion according to the contour information of the abnormal protrusion; Based on the contour line, obtaining a difference between a grayscale value of a first area and a grayscale value of a second area, wherein the first area is an area formed by extending the contour line outward by a first distance, and the first area is located outside the contour line, and the second area is an area formed by extending the contour line inward by the first distance, and the second area is located inside the contour line; Determine whether the difference between the grayscale value of the first area and the grayscale value of the second area is within a set range; If the difference is within the set range, it is determined that the abnormal protrusion is formed below the surface of the anode close to the flat layer, and the abnormal protrusion is a first type of abnormal protrusion.

4. The method for preparing a display panel according to claim 2 or 3, characterized in that: Removing the abnormal protrusion so that the anode forms a hole corresponding to the area of ​​the abnormal protrusion comprises the following steps: According to the position information and the contour information of the abnormal protrusion, the abnormal protrusion is removed to form a hole, and the depth of the hole is greater than or equal to the thickness of the anode.

5. The method for preparing a display panel according to claim 4, characterized in that: Filling the excavated hole with a repair material comprises the following steps: Acquiring film layer information of the anode, wherein the film layer information includes the number of film layers, material information of each film layer, and thickness information of each film layer; If the number of the membrane layer is one layer, the same material as that of the anode is selected as the repair material to fill the hole; If the number of the membrane layers is at least two, the same material as the thickest membrane layer in the anode is selected as the repair material to fill the hole, or, according to the order of the membrane layers, the same material as the corresponding membrane layers in the anode is selected in turn as the repair material to repair the hole.

6. The method for preparing a display panel according to claim 3, characterized in that: After determining whether the difference between the grayscale value of the first area and the grayscale value of the second area is within a set range, the method further includes the following steps: If the difference is not within the set range, it is determined that the abnormal protrusion is formed on the surface of the anode away from the flat layer, and the abnormal protrusion is a second type of abnormal protrusion.

7. The method for preparing a display panel according to claim 6, characterized in that: Removing the abnormal protrusion so that the anode forms a hole corresponding to the area of ​​the abnormal protrusion comprises the following steps: According to the position information and the contour information of the second type of abnormal protrusions, the abnormal protrusions are removed to form a hole, wherein the depth of the hole is less than the thickness of the anode; Filling the excavated hole with a repair material also includes the following steps: Acquiring film layer information of the anode, wherein the film layer information includes the number of film layers and material information of each film layer; The same material as the film layer in the anode that is in direct contact with the second type of abnormal protrusion is selected as the repair material to fill the hole.

8. The method for preparing a display panel according to any one of claims 2-3 and 6-7, characterized in that: Removing the abnormal protrusion to form a hole also includes the following steps: According to the position information and the contour information of the abnormal protrusion, the contour line information of the hole is obtained and a first contour line trajectory of the hole is generated, wherein the first contour line trajectory of the hole is formed by extending the contour line of the abnormal protrusion outward by a second distance, and the second distance is between 0.4 micrometers and 1 micrometer; determining whether the first contour line trajectory is within the inner contour of the opening; If the first contour line trajectory is within the inner contour of the opening, the abnormal protrusion is removed according to the first contour line trajectory to form the excavated hole.

9. The method for preparing a display panel according to claim 8, characterized in that: Determining whether the first contour line trajectory is within the inner contour of the opening, and then further comprising the following steps: If a portion of the first contour line track exceeds the inner contour of the opening, removing the portion of the first contour line track exceeding the inner contour of the opening to generate a second contour line track; According to the second contour line trajectory, the abnormal protrusion is removed to form the hole.

10. The method for preparing a display panel according to claim 9, characterized in that: The repair material is filled in the hole by inkjet printing, and the abnormal protrusion is removed by laser.

11. A display panel, characterized in that: include: A driving substrate, comprising a planar layer, an anode and a pixel definition layer, wherein the anode is arranged on the planar layer, the pixel definition layer is arranged on the anode, a plurality of openings are provided on the pixel definition layer, one opening correspondingly exposes one anode, a hole is provided on the anode, the hole is filled with a repair material, and the repair material is at least partially the same as the material of the anode; a light-emitting layer covering the anode and the repair material; A cathode covers the light-emitting layer.

12. The display panel according to claim 11, characterized in that: The anode is a single film layer, and the repair material is consistent with the material of the anode; Alternatively, the depth of the hole is greater than or equal to the thickness of the anode, the anode is formed by stacking at least two first film layers, the repair material is formed by stacking at least two second film layers, and the first film layer and the second film layer arranged in the same layer are made of the same material; Alternatively, the depth of the hole is greater than or equal to the thickness of the anode, the anode is formed by stacking at least two first film layers, and the repair material is the same as the material of the thickest film layer in the anode; Alternatively, the depth of the hole is smaller than the thickness of the anode, the anode is formed by stacking at least two film layers, and the repair material is the same as the material of the film layer in the anode that is farthest from the flat layer.

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