Display panel and manufacturing method thereof

Abstract

The embodiment of the present application discloses a display panel and a method for manufacturing the same, comprising the following steps: acquiring a real-time image within the opening area, identifying an abnormal protrusion and acquiring position information of the abnormal protrusion based on a comparison between the real-time image and a standard image; flipping the drive substrate so that the opening faces downward; removing the abnormal protrusion based on the position information, so that the anode forms a hole corresponding to the area of ​​the abnormal protrusion; flipping the drive substrate again so that the opening faces upward; and filling the hole with a repair material. The display panel and method for manufacturing the same in the embodiment of the present application remove the abnormal protrusion after flipping the drive substrate, thereby reducing the risk of the removed abnormal protrusion adhering to the drive substrate, and at the same time, improving dark spot defects by excessively removing the abnormal protrusion; then filling the hole with a repair material to improve the surface flatness of the anode.

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 significantly impacts OLED product yield is the high number of dark spots, making it difficult to meet customer specifications. The high incidence of dark spots is often due to tiny foreign matter in the OLED device's anode, metal material protrusions, and microscopic residue in the pixel definition layer. Currently, the mainstream approach is to identify and eliminate dark spots using techniques such as aging tests. However, this approach only reduces the dark spot's impact, making it difficult for the human eye to detect from a distance, and does not completely eliminate the dark spots at their 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: the first type of dark spot is caused by the bulge caused by the precipitation of anode metal, which causes the cathode and anode to short-circuit and produce dark spots; the second type of dark spot is caused by foreign matter under the anode causing the anode film to bulge, which causes the cathode and anode to short-circuit and produce dark spots; the third type of dark spot is caused by the material residue or micro-residue of the pixel definition layer, which causes the ink of the organic light-emitting layer to spread unevenly, causing the cathode and 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 includes 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 being disposed on the planar layer, the pixel definition layer being disposed on the anode, the pixel definition layer being provided with a plurality of openings, each opening correspondingly exposing one anode;

[0007] Acquiring a real-time image within the opening area, identifying abnormal protrusions based on a comparison between the real-time image and a standard image, and acquiring position information of the abnormal protrusions;

[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 a hole is formed in the anode corresponding to the area of ​​the abnormal protrusion;

[0010] Turning over the drive 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 based on 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 grayscale value of the local area of ​​the real-time image is greater than the standard grayscale 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 region and a grayscale value of a second region, where the first region is formed by extending the contour line outward by a first distance and is located outside the contour line, and the second region is formed by extending the contour line inward by the first distance and 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 a hole is formed in the anode 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 includes 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, 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 are 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 region and the grayscale value of the second region 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 a hole is formed in the anode 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 abnormal protrusion, the abnormal protrusion is 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 repairing 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] Acquiring contour line information of the hole and generating a first contour line trajectory of the hole based on the position information and contour information of the abnormal protrusion, 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, wherein 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 excavation 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 that exceeds 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 excavated 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, comprising:

[0043] A driving substrate comprising a planar layer, an anode, and a pixel definition layer, wherein the anode is disposed on the planar layer, the pixel definition layer is disposed on the anode, the pixel definition layer is provided with a plurality of openings, each opening corresponding to an anode exposed, and the anode is provided with a hole, the hole being filled with a repair material, the repair material being 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 layers and the second film layers 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, based on the removal of the abnormal protrusions, holes are left to excessively remove the abnormal protrusions, reducing the risk of short circuit between the anode and the cathode, thereby improving the dark spot defect; then, a repair material is used to fill the holes left after removing the abnormal protrusions, thereby improving the surface flatness of the anode, thereby improving the uniformity of the thickness of the light-emitting layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Figure 1 is a schematic flow chart of a method for manufacturing 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 manufacturing 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 manufacturing 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 manufacturing 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 manufacturing a display panel provided in an embodiment of the present application;

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

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

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

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

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

[0062] Figure 12 This is another structural schematic diagram of the display panel provided in an 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 embodiments described 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 making creative efforts are within the scope of protection of this application. In addition, it should be understood that the specific embodiments described here are only used to illustrate and explain the present application and are not used to limit the present application. In this application, the various embodiments can be combined with each other but will not be repeated one by one. In addition, unless otherwise specified, the directional words used, such as "upper" and "lower", generally refer to the upper and lower parts of the device in actual use or working state, specifically the drawing direction in the drawings; while "inner" and "outer" refer to the outline of the device; the terms "first", "second", "third", etc. are used only as labels and do not impose numerical requirements or establish an order.

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

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

[0066] A driving substrate is provided, 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, and a plurality of openings are opened on the pixel definition layer, wherein one opening exposes one anode.

[0067] A real-time image within 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] The abnormal protrusion is removed according to the position information, 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, based on the removal of the abnormal protrusions, holes are left to excessively remove the abnormal protrusions, reducing the risk of short circuit between the anode and the cathode, thereby improving the dark spot defect; then, a repair material is used to fill the holes left after removing the abnormal protrusions, thereby improving the surface flatness of the anode, thereby 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 being arranged on the planar layer, the pixel definition layer being arranged on the anode, and a plurality of openings being opened on the pixel definition layer, each opening correspondingly exposing one anode.

[0076] Step B2: acquiring a real-time image within the opening area, and identifying abnormal protrusions and acquiring position information of the abnormal protrusions based on a 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 a hole is formed in the anode corresponding to the area of ​​the abnormal protrusion.

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

[0080] Step B6: Fill the 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 manufacturing a display panel according to an embodiment of the present application.

[0083] Please refer to Figure 2 In step B1, a driving substrate 11 is provided. 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 has a plurality of openings 11a, with each opening 11a exposing 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. However, the present invention is not limited thereto. For example, the anode 112 is a single-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 planar layer 111, such as protrusions 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 planar layer 111, such as protrusions formed by residual material of the pixel definition layer and / or protrusions caused by metal precipitation from the anode 112.

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

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

[0092] Then go to step B2.

[0093] Step B2: acquiring a real-time image within the opening 11a area, and identifying abnormal protrusions and acquiring position information of the abnormal protrusions based on comparison between the real-time image and the standard image.

[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 area in the driving substrate 11. For example, an optical inspection device (AOI) may be used to obtain the real-time image.

[0095] Then, the real-time image and the standard image are compared to identify abnormal protrusions and record the corresponding position information of the abnormal protrusions. Among them, this step and the step of obtaining the real-time image can both 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 based on 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; 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 grayscale value is the standard grayscale value when the anode 112 is in a flat state. The setting of the standard grayscale 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 subject during shooting, and the exposure level during shooting. Therefore, the standard grayscale 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 from multiple angles, and the abnormal protrusion protruding from the anode 112 may be accurately identified through the 3D image.

[0101] Then go to step B22.

[0102] Step B22: Acquire the position information and contour information of the abnormal protrusion based on the real-time image.

[0103] It is understood 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 be further included:

[0105] Step B23: Obtain 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 the contour information of the abnormal protrusion being used, the contour line of the abnormal protrusion in the real-time image is obtained, and 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 an area formed by expanding 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 expanding the contour line inward by the first distance, and the second area is located inside the contour line.

[0108] It is understood that the area within the outline is the abnormal protrusion, and the area outside the outline is the local area of ​​the anode 112. In other words, the first area is the local area of ​​the anode 112, and the second area is the 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 grayscale value difference between the first region and the second region is obtained to determine whether the abnormal protrusion belongs to the first type of abnormal protrusion or the second type of abnormal protrusion. Because the first type of abnormal protrusion is formed below the anode 112 and is covered by the anode 112, the boundary outline of the first type of abnormal protrusion p1 is relatively blurred; while the second type of abnormal protrusion is formed above the anode 112, the boundary outline of the second type of abnormal protrusion p2 is relatively clear.

[0112] Because the boundary is clear, the grayscale values ​​of the inner and outer regions (the first region and the second region) representing the contour line have a large difference. The larger the difference in grayscale value, the clearer the boundary is, and the smaller the difference in grayscale value, the more blurred the boundary is.

[0113] It is 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: Determine 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 a larger grayscale value difference indicates a clearer boundary outline, while a smaller grayscale value difference indicates a more blurred boundary outline, the set range can be defined as a smaller range or a larger range. When the grayscale value difference between the first and second regions is within the smaller set range, the abnormal protrusion is determined to be a first-type abnormal protrusion p1; when the grayscale value difference between the first and second regions is within the larger set range, the abnormal protrusion is determined 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 is not limited by the present application.

[0118] Then go to step B26.

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

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

[0121] In addition, in some embodiments, the angle of the camera can 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, its light reflection degree at different angles varies little and is relatively stable. However, the second type of abnormal protrusion p2 is above the anode 112, so its light reflection degree at different angles varies greatly.

[0123] Therefore, the degree of grayscale difference between the abnormal protrusions in real-time images at different angles can be used to assist in determining whether the abnormal protrusion is a first-type abnormal protrusion p1 or a second-type abnormal protrusion p2. If the grayscale difference between the abnormal protrusions in the real-time images at multiple angles is within a threshold range, the abnormal protrusion is determined to be a first-type abnormal protrusion p1. If the grayscale difference between the abnormal protrusions in the real-time images at multiple angles is within the threshold range, the abnormal protrusion is determined to be a 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 go 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 drive substrate 11 is flipped from facing up to facing down, with the opening 11a facing downward. This arrangement allows the abnormal protrusion material that has been separated from the drive substrate 11 to fall due to gravity when the abnormal protrusion is removed, reducing the risk of the discarded abnormal protrusion material reattaching to the drive substrate 11 and forming abnormal particles.

[0128] Then go to step B4.

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

[0130] Optionally, the abnormal protrusion is removed based on the position signal and contour information of the abnormal protrusion, wherein the abnormal protrusion can be removed by laser.

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

[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 the 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, thereby improving 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: determine 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 part of the first contour line trajectory exceeds the inner contour of the opening 11a, remove the part 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 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 and reduce 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 , based on the position information and the contour information of the abnormal protrusion or the first type of abnormal protrusion p1 , removing the abnormal protrusion to form a hole g1 , wherein the depth of the hole g1 is greater than or equal to the thickness of the anode 112 .

[0143] It is understandable that, based on the position and contour information of the abnormal protrusions, the region corresponding to the abnormal protrusions on the anode 112 can be directly dug through to completely remove the abnormal protrusions. This approach is applicable to both the first type of abnormal protrusions p1 and the second type of abnormal protrusions p2. In other words, the first type of abnormal protrusions p1 and the second type of abnormal protrusions p2 can be removed uniformly by digging through the anode 112, eliminating the step of identifying the first type of abnormal protrusions p1 and the second type of abnormal protrusions p2.

[0144] exist Figure 4 In the embodiment, 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, as Figure 4 As shown, the first type of abnormal protrusion p1 may adopt one digging method, and the second type of abnormal protrusion p2 may adopt another 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 a hole is formed in the anode 112 corresponding to the area of ​​the abnormal protrusion, further includes the following steps:

[0148] Step B46 , based on 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 , where the depth of the hole g1 is less than the thickness of the anode 112 .

[0149] Because 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 repair costs and improving repair efficiency in 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. In other words, 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 the hole g1 does not touch the reflective metal film layer y2 for the second type of abnormal protrusion p2.

[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 in order 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 dark spot effect.

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

[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, filling the hole g1 with a repair material, 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 layers, 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; 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 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 part 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 part 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 part 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, filling the hole g1 with a repair material, 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 layers, 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 direct contact with the second type of abnormal protrusion p2 in the anode 112 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 Figure 9 , step B7, forming the light-emitting layer 12 and the cathode 13 in sequence on the anode 112.

[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 manufactured by the method for manufacturing a display panel according to any one of the above embodiments.

[0176] The display panel 100 includes a drive substrate 11, a light-emitting layer 12, and a cathode 13. The drive 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. The pixel definition layer 113 has multiple openings 11a, with each opening 11a exposing a corresponding anode 112. The anode 112 has a hole g1 formed therein, which is filled with a repair material x1. The repair material x1 is at least partially the same material as 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 the repair material x1 to repair the hole g1 left after removing the abnormal protrusion, thereby improving the dark spot defect and increasing 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 thickest film layer in the anode 112, such as Figure 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 farthest from the flat layer 111 in the anode 112, such as Figure 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 provided in the same layer are made of the same material, such as Figure 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 Figure 12 shown.

[0183] The display panel of the embodiment of the present application is based on removing the abnormal protrusion and leaving a hole g1, so as to excessively remove the abnormal protrusion, reduce the risk of short circuit between the anode 112 and the cathode 13, and thus improve 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, based on the ideas of the present application, there will be changes in the specific implementation methods 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 being disposed on the planar layer, the pixel definition layer being disposed on the anode, the pixel definition layer being provided with a plurality of openings, each opening correspondingly exposing one anode; Acquiring a real-time image within the opening area, identifying abnormal protrusions based on a comparison between the real-time image and a standard image, and acquiring position information of the abnormal protrusions; Turning over the driving substrate so that the opening faces downward; 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; Turning over the drive 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 manufacturing a display panel according to claim 1, wherein: Identifying abnormal protrusions and obtaining position information of the abnormal protrusions based on comparison between the real-time image and the standard image includes the following steps: According to the comparison between the real-time image and the standard image, determining whether the grayscale value of the local area of ​​the real-time image is greater than the standard grayscale 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 manufacturing a display panel according to claim 2, wherein: 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 region and a grayscale value of a second region, where the first region is formed by extending the contour line outward by a first distance and is located outside the contour line, and the second region is formed by extending the contour line inward by the first distance and 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 manufacturing a display panel according to claim 2 or 3, wherein: Removing the abnormal protrusion so that a hole is formed in the anode corresponding to the abnormal protrusion includes 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 manufacturing a display panel according to claim 4, wherein: Filling the excavated hole with a patching 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, 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 are selected in turn as the repair material to repair the hole.

6. The method for manufacturing a display panel according to claim 3, wherein: 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 manufacturing a display panel according to claim 6, wherein: Removing the abnormal protrusion so that a hole is formed in the anode corresponding to the abnormal protrusion includes the following steps: According to the position information and the contour information of the second-type abnormal protrusion, the abnormal protrusion is 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 repairing material to fill the hole.

8. The method for manufacturing 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 further includes the following steps: Acquiring contour line information of the hole and generating a first contour line trajectory of the hole based on the position information and contour information of the abnormal protrusion, 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, wherein 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 excavation hole.

9. The method for manufacturing a display panel according to claim 8, wherein: After determining whether the first contour line trajectory is within the inner contour of the opening, the following steps are further included: 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 that exceeds 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 excavated hole.

10. The method for manufacturing a display panel according to claim 9, wherein: The repair material is filled in the excavated 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 disposed on the planar layer, the pixel definition layer is disposed on the anode, the pixel definition layer is provided with a plurality of openings, each opening corresponding to an anode exposed, and the anode is provided with a hole, the hole being filled with a repair material, the repair material being 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, wherein: 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 layers and the second film layers 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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