Display panel and preparation method thereof

Abstract

The invention relates to the technical field of display, in particular to a display panel and a preparation method thereof. The display panel comprises a substrate and a plurality of organic layer groups which are sequentially stacked on the substrate, wherein each organic layer group comprises at least one organic layer; the display panel is provided with a first boundary area, at least part of the organic layer group forms a plurality of first edges staggered in the first direction in the first boundary area, and the height of the first edges is not larger than the thickness of the three organic layers; the display panel further comprises a first protective film which covers the first boundary area. The display panel can reduce the probability of forming wrinkles and improve the utilization rate of equipment.

Description

Technical Field

[0001] The present disclosure relates to the field of display technologies, and more particularly, to a display panel and a method for manufacturing the same. Background Art

[0002] Products with a design of four or more organic layers have wrinkles after being separated by the DLM process (the DLM process mainly separates the protective film from the glass carrier through a blade. In this way, the flexible product is completely separated from the carrier Glass, completing the conversion from rigid to flexible). After being laser cut by the BLM (BLM laser cutting machine), the wrinkles form through holes, which affect the subsequent vacuum adsorption process and the equipment operation rate.

[0003] It should be noted that the information disclosed in the above background art section is only used to enhance the understanding of the background of the present disclosure, and thus may include information that does not constitute the prior art known to those of ordinary skill in the art. Summary of the Invention

[0004] The purpose of the present disclosure is to overcome the above-mentioned deficiencies of the prior art and provide a display panel and a method for manufacturing the same, which can reduce the probability of forming wrinkles.

[0005] According to one aspect of the present disclosure, a display panel is provided, including a substrate and a plurality of organic layer groups sequentially stacked on the substrate, each organic layer group including at least one organic layer;

[0006] The display panel has a first boundary region, and at least part of the organic layer groups form a plurality of first edges staggered in a first direction in the first boundary region, and the height of the first edges is not greater than the thickness of three layers of the organic layers;

[0007] The display panel further includes a first protective film covering the first boundary region.

[0008] In an embodiment of the present disclosure, at least part of the organic layers form a first surface in the first boundary region, and at least part of the organic layers and the substrate form a second surface in the first boundary region;

[0009] The step difference between adjacent two first surfaces and between the adjacent first surface and the second surface is not greater than the thickness of three layers of the organic layers.

[0010] In an embodiment of the present disclosure, the display panel has a panel area and a removal area; the first boundary region is located in the removal area.

[0011] In an embodiment of the present disclosure, the total number of the organic layers is not less than 4.

[0012] In an embodiment of the present disclosure, each organic layer group includes two adjacent organic layers; the edges of the two organic layers within the same organic layer group are flush to form the first edge;

[0013] In the direction away from the substrate, each of the first edges gradually approaches the center of the display panel.

[0014] In an embodiment of the present disclosure, each organic layer group includes one organic layer; the edge of each organic layer is the first edge;

[0015] In the direction away from the substrate, each of the first edges gradually approaches the center of the display panel.

[0016] In an embodiment of the present disclosure, the number of organic layers within the organic layer group is the same, and each organic layer group includes three organic layers;

[0017] In two adjacent organic layer groups, the organic layer in the middle of the lower organic layer group gradually decreases in thickness in the direction away from the center of the display panel to form a first inclined surface, and the orthographic projection of the first inclined surface on the substrate overlaps with the orthographic projection of the organic layer below it on the substrate. The edge of the organic layer above it is flush with the second side edge of the first inclined surface to form a second inclined surface and the first edge of the organic layer group;

[0018] In the upper organic layer group, the organic layer away from the substrate covers all the organic layers below it and covers the second inclined surface. The upper organic layer forms a step structure at the same height as the first side of the second inclined surface. The first side surface of the step structure forms the first edge, and the second side surface of the step structure is flush with the first edge of the lower organic layer group.

[0019] In an embodiment of the present disclosure, in two adjacent organic layer groups, the number of organic layers in the lower organic layer group is four, and the number of organic layers in the upper organic layer group is two;

[0020] The organic layer in the middle of the lower organic layer group gradually decreases in thickness in the direction away from the center of the display panel to form a first inclined surface, and the orthographic projection of the first inclined surface on the substrate overlaps with the orthographic projection of the organic layer below it on the substrate. The edge of the organic layer above it is flush with the second side edge of the first inclined surface to form a second inclined surface and the first edge of the organic layer group;

[0021] In the upper organic layer group, the edges of the organic layers are flush to form the first edge.

[0022] In an embodiment of the present disclosure, the display panel has a panel area and a removal area;

[0023] The panel area has a plurality of sub-panel areas and a cutting area surrounding the periphery of each sub-panel area, wherein part of the organic layer only extends to the cutting area.

[0024] In an embodiment of the present disclosure, the number of organic layers in the organic layer group is the same, and each organic layer group includes three organic layers;

[0025] In the lower organic layer group, the organic layer in the middle covers the organic layer below it, and the edge of the organic layer above it is flush with the edge of the organic layer in the middle, forming a first edge;

[0026] In the upper organic layer group, part of the organic layer below only extends to the cutting area; the edge of the organic layer above forms a first edge, and the first edge of the upper organic layer group is located on the side closer to the center of the display panel than the first edge of the first organic layer group.

[0027] In an embodiment of the present disclosure, the horizontal distance between two adjacent first edges is not less than 300 micrometers.

[0028] In an embodiment of the present disclosure, the organic layer includes a planarization layer.

[0029] According to another aspect of the present disclosure, a method for manufacturing a display panel is provided, including forming the above display panel.

[0030] It should be understood that the above general description and the following detailed description are only exemplary and explanatory, and cannot limit the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The accompanying drawings herein are incorporated into the specification and form a part of the specification, showing embodiments consistent with the present disclosure, and are used together with the specification to explain the principles of the present disclosure. Obviously, the accompanying drawings in the following description are only some embodiments of the present disclosure, and those of ordinary skill in the art can obtain other drawings based on these drawings without creative efforts.

[0032] Figure 1 It is a schematic structural diagram of a display panel in an embodiment of the present disclosure.

[0033] Figure 2 It is a schematic structural diagram of a display panel in an embodiment of the present disclosure.

[0034] Figure 3 It is a schematic structural diagram of a display panel in an embodiment of the present disclosure.

[0035] Figure 4 In one embodiment of the present disclosure, it is a schematic structural diagram of a display panel.

[0036] Figure 5 In one embodiment of the present disclosure, it is a schematic structural diagram of a display panel.

[0037] Figure 6 In one embodiment of the present disclosure, it is a schematic structural diagram of a display panel.

[0038] Figure 7 In one embodiment of the present disclosure, it is a schematic structural diagram of a display panel.

[0039] Figure 8 In one embodiment of the present disclosure, it is a schematic structural diagram of a display panel. Detailed implementation manners

[0040] Example embodiments will now be described more fully with reference to the accompanying drawings. However, the example embodiments can be implemented in various forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the example embodiments to those skilled in the art. Like reference numerals in the figures denote like or similar structures, and thus their detailed descriptions will be omitted. In addition, the drawings are only schematic illustrations of the present disclosure and are not necessarily drawn to scale.

[0041] Although relative terms such as "upper" and "lower" are used in this specification to describe the relative relationship of one component of an icon to another component, these terms are used in this specification only for convenience, for example, according to the directions of the examples described in the drawings. It can be understood that if the device of the icon is turned upside down, the component described as "upper" will become the component described as "lower". When a structure is "on" another structure, it may mean that a structure is integrally formed on another structure, or that a structure is "directly" disposed on another structure, or that a structure is "indirectly" disposed on another structure through another structure.

[0042] The terms "a", "an", "the", and "said" are used to indicate the existence of one or more elements / components / etc.; the terms "comprising" and "having" are used to indicate an open inclusion meaning and mean that there may be additional elements / components / etc. in addition to the listed elements / components / etc.; the terms "first", "second", and "third", etc. are used only as labels and are not a limitation on the quantity of their objects.

[0043] In this application, unless otherwise clearly specified or limited, the term "connection" shall be understood in a broad sense. For example, "connection" can be a fixed connection, a detachable connection, or an integral body; it can be directly connected or indirectly connected through an intermediate medium.

[0044] In an embodiment of the present disclosure, a thin film transistor (Thin Film Transistor, abbreviated as TFT) includes an active layer, a gate insulating layer, and a gate that are stacked. Among them, the active layer is located in the semiconductor layer, and the active layer includes a channel region and a source electrode and a drain electrode respectively located on both sides of the channel region. Among them, the channel region maintains semiconductor characteristics, and both the source electrode and the drain electrode are conductorized. In an embodiment of the present disclosure, in the case of using transistors with opposite polarities or in the case of a change in the current direction during circuit operation, etc., the functions of the "source electrode" and the "drain electrode" sometimes swap with each other, that is, the "drain electrode" and the "source electrode" can swap with each other. In an embodiment of the present disclosure, for any one transistor, one of the "source electrode" and the "drain electrode" is referred to as the first pole of the transistor, and the other is referred to as the second pole of the transistor.

[0045] In this article, the first surface refers to the surface parallel to the substrate (in this article, A is parallel to B, which means the deviation between A and B is not greater than 10°).

[0046] The height of the first edge refers to the height of the first edge along the arrangement direction of each organic layer.

[0047] In this article, C is flush with D means that C and D are on the same vertical line or horizontal line, or the deviation between C and D is not greater than 10°.

[0048] In the present disclosure, when describing that structure E and structure F are overlapped, it means that structure E and structure F are respectively in different film layers, but the orthographic projection of structure E on the substrate and the orthographic projection of structure F on the substrate at least partially overlap.

[0049] See Figure 1 ( Figure 1 is a simplified diagram), the present disclosure provides a display panel PNL, which includes a panel area NL and a removal area QC. The panel area NL has a plurality of sub-panel areas NLA and a cutting area NLB surrounding the periphery of each sub-panel area NLA. The display panel PNL can be cut into a plurality of sub-panels by cutting in the cutting area NLB, and the sub-panel can be used as part of a display module for display. It can be understood that the removal area QC and the sub-panel NLA are isolated by the cutting area NLB.

[0050] See Figure 2 , the display panel PNL may include an organic substrate SBT, a driving layer DRL, and a pixel layer PIXL that are sequentially stacked.

[0051] In some embodiments of the present disclosure, the organic substrate SBT can be a flexible substrate SBT, and its material can be polyimide. Of course, in other examples, the organic substrate SBT can also be other flexible materials not shown. In some other embodiments, the organic substrate SBT can also be a composite of multiple layers of materials. For example, the organic substrate SBT can include a bottom film layer (Bottom Film), a pressure-sensitive adhesive layer, a first polyimide layer, and a second polyimide layer that are sequentially stacked.

[0052] The driving layer DRL is provided with a pixel driving circuit. In the driving layer DRL, any one pixel driving circuit can include a transistor and a storage capacitor. Further, the transistor can be a thin film transistor, and the thin film transistor can be selected from a top-gate thin film transistor, a bottom-gate thin film transistor, or a double-gate thin film transistor; the material of the active layer of the thin film transistor can be an amorphous silicon semiconductor material, a low-temperature polycrystalline silicon semiconductor material, a metal oxide semiconductor material, an organic semiconductor material, or other types of semiconductor materials; the thin film transistor can be an N-type thin film transistor or a P-type thin film transistor.

[0053] It can be understood that among the transistors in the pixel driving circuit, the types of any two transistors can be the same or different. Exemplarily, in one embodiment, in a pixel driving circuit, some transistors can be N-type transistors and some transistors can be P-type transistors. Another example is that in another embodiment of the present disclosure, in a pixel driving circuit, the material of the active layer of some transistors can be a low-temperature polycrystalline silicon semiconductor material, and the material of the active layer of some transistors can be a metal oxide semiconductor material. In some embodiments of the present disclosure, the thin film transistor is a low-temperature polycrystalline silicon transistor. In some other embodiments of the present disclosure, some thin film transistors are low-temperature polycrystalline silicon transistors and some thin film transistors are metal oxide transistors.

[0054] Optionally, the driving layer DRL may include a semiconductor layer SCL, a gate insulating layer GI, a gate layer GT, an interlayer dielectric layer ILD, a source-drain metal layer SD, etc., which are stacked between the organic substrate SBT and the pixel layer PIXL. Each thin-film transistor and storage capacitor may be formed by film layers such as the semiconductor layer SCL, the gate insulating layer GI, the gate layer GT, the interlayer dielectric layer ILD, and the source-drain metal layer SD. Among them, the positional relationship of each film layer may be determined according to the film layer structure of the thin-film transistor. Further, the semiconductor layer SCL may be used to form the channel region of the transistor; the gate layer may be used to form gate layer traces such as scan leads, reset control leads, and light emission control leads, may also be used to form the gate of the transistor, and may also be used to form part or all of the electrode plates of the storage capacitor; the source-drain metal layer may be used to form source-drain metal layer traces such as data leads and driving power leads, and may also be used to form part of the electrode plates of the storage capacitor.

[0055] For example, in some embodiments of the present disclosure, the driving layer DRL may include a semiconductor layer SCL, a gate insulating layer GI, a gate layer GT, an interlayer dielectric layer ILD, and a source-drain metal layer SD that are sequentially stacked. The thin-film transistor thus formed is a top-gate thin-film transistor.

[0056] For another example, in some embodiments of the present disclosure, the driving layer DRL may include a gate layer GT, a gate insulating layer GI, a semiconductor layer SCL, an interlayer dielectric layer ILD, and a source-drain metal layer SD that are sequentially stacked. The thin-film transistor thus formed is a bottom-gate thin-film transistor.

[0057] In some embodiments, the semiconductor layer SCL may be one layer, or may be set to two or three layers according to needs. For example, the semiconductor layer may include a first semiconductor layer SCL1 and a second semiconductor layer SCL2. The gate layer may be two or three layers. For example, the gate layer GT may include a first gate layer GT1, a second gate layer GT2, and a third gate layer GT3. The gate insulating layer may include a first gate insulating layer GI1 for isolating the first semiconductor layer SCL1 and the first gate layer GT1, and a second gate insulating layer GI2 and a third gate insulating layer GI3 for isolating the second semiconductor layer SCL2 and the second gate layer GT2 and the third gate layer GT3. In an example of the present disclosure, the second semiconductor layer SCL2 is sandwiched between the second gate layer GT2 and the third gate layer GT3. Thus, in cooperation with other film layers between the layers, a transistor with a double-gate structure can be formed. In one example, the driving layer DRL may further include a second metal shielding layer BLB located between the first gate layer GT1 and the second gate layer GT2. In one example, the driving layer DRL may further include a first metal shielding layer BLA located between the substrate SBT and the first semiconductor layer SCL1. Exemplarily, refer toFigure 2 , the driving layer DRL may include a first metal shielding layer BLA, a first semiconductor layer SCL1, a first gate insulating layer GI1, a first gate layer GT1, a second metal shielding layer BLB, a second gate layer GT2, a second gate insulating layer GI2, a second semiconductor layer SCL2, a third gate insulating layer GI3, a third gate layer GT3, an interlayer dielectric layer ILD, and a source / drain metal layer SD, which are sequentially stacked on one side of the organic substrate SBT. In an example of the present disclosure, the first semiconductor layer SCL1 may be a low-temperature polycrystalline silicon semiconductor layer, and the second semiconductor layer SCL2 may be a metal oxide semiconductor layer.

[0058] In an embodiment of the present disclosure, the source / drain metal layer may be one layer or multiple layers. When the number of source / drain metal layers is multiple, an organic layer, such as a planarization layer, may be interposed between any two adjacent source / drain metal layers. For example, in an embodiment of the present disclosure, the source / drain metal layer may include a first source / drain metal layer SD1, a second source / drain metal layer SD2, and a third source / drain metal layer SD3, which are sequentially stacked on the side of the interlayer dielectric layer ILD away from the substrate SBT; an organic layer OL, such as a planarization layer, may be interposed between any two adjacent source / drain metal layers SD. It can be understood that the driving layer DRL includes a first planarization layer PLN1, a second planarization layer PLN2, and a third planarization layer PLN3; in an example, the driving layer DRL further includes a first source / drain metal layer SD1, a first planarization layer PLN1, a second source / drain metal layer SD2, a second planarization layer PLN2, a third source / drain metal layer SD3, and a third planarization layer PLN3, which are sequentially stacked on the interlayer dielectric layer ILD. In an example, for the convenience of routing, a fourth planarization layer PLN4, a fifth planarization layer PLN5, and a sixth planarization layer PLN6 are sequentially provided on the side of the third planarization layer PLN3 away from the third source / drain metal layer SD3. Of course, in an example, the organic layers OL interposed between any two adjacent source / drain metal layers may also be different. Optionally, the driving layer DRL may further include a passivation layer, and the passivation layer may be provided on the surface of the third source / drain metal layer SD3 away from the organic substrate SBT to protect the source / drain metal layer.

[0059] Optionally, the driving layer DRL may further include an inorganic buffer layer BRR provided between the organic substrate SBT and the first semiconductor layer SCL1, and the remaining semiconductor layers SCL, gate layers GT, and other film layers are all located on the side of the inorganic buffer layer BRR away from the organic substrate SBT. The material of the inorganic buffer layer BRR may be an inorganic insulating material such as silicon oxide or silicon nitride. The buffer material layer may be a single layer of inorganic material or multiple layers of stacked inorganic materials. In an example, the inorganic buffer layer BRR may cover the substrate SBT.

[0060] Optionally, the driving layer DRL may further include an inorganic barrier layer disposed between the organic substrate SBT and the inorganic buffer layer BRR. The barrier layer can shield the organic substrate SBT to prevent the components in the organic substrate SBT from penetrating into the semiconductor layer and affecting the stability of the pixel driving circuit.

[0061] In one example, the driving layer DRL further includes a first source-drain metal layer SD1, a first planarization layer PLN1, a second source-drain metal layer SD2, a second planarization layer PLN2, a third source-drain metal layer SD3, a third planarization layer PLN3, a fourth planarization layer PLN4, a fifth planarization layer PLN5, and a sixth planarization layer PLN6, which are sequentially stacked on the interlayer dielectric layer ILD.

[0062] Of course, the specific structure of the driving layer DRL is not limited to the above form, and the driving layer DRL may include other film layers.

[0063] In an embodiment of the present disclosure, each organic layer OL (planarization layer PLN) extends to the removal area QC.

[0064] In the related art, when the number of organic layers OL is relatively large (4 or more), during the DLM technology (see Figure 8 , the DLM technology mainly refers to separating the protective film from the substrate support layer through a blade. In this way, the flexible product is completely separated from the substrate support layer. The rigid-to-flexible conversion is completed), wrinkles will appear in the removal area QC. After the BLM process, these wrinkles form through-holes, which affect the subsequent vacuum adsorption process and the equipment operation rate.

[0065] To solve at least one of the above problems, the structure of the organic layer OL in the removal area QC is optimized. Specifically, see Figures 3 - 8, the display panel PNL includes a substrate SBT and a plurality of organic layer groups sequentially stacked on the substrate SBT, each organic layer group including at least one organic layer OL; the display panel PNL has a first boundary region BOR1, and at least part of the organic layer groups form a plurality of first edges EG1 staggered along a first direction H1 in the first boundary region BOR1, and the height of the first edges EG1 is not greater than the thickness of three organic layers OL; the display panel PNL further includes a first protective film TP1, and the first protective film TP1 covers the first boundary region BOR1 through an adhesive OC. In the present disclosure, the first direction H1 refers to the direction parallel to the substrate SBT, and the height refers to the vertical distance along the arrangement direction of the plurality of organic layers OL. It can be understood that each organic layer OL has a first edge EG1 in the first boundary region BOR1, and a first surface SF1 is formed between the plurality of first edges EG1, and the step difference between adjacent two first surfaces SF1 is not greater than the thickness of three organic layers OL. In the present disclosure, by limiting the step difference between the respective first surfaces SF1 formed by the organic layers OL of the display panel PNL in the removal area QC to be not greater than the thickness of three organic layers OL (the height of the first edge EG1 is not greater than the thickness of three organic layers OL), a stepped structure is formed between the edges of the plurality of organic layers OL. Compared with the scheme in which the edges of each organic layer in the removal area QC are parallel, the step difference is reduced, and the probability of wrinkles appearing is reduced.

[0066] In this example, the substrate SBT and the buffer layer BRR extend to the removal area QC, the buffer layer BRR covers the substrate SBT, and a second edge EG2 is formed in the first boundary region BOR1. The orthographic projection of each organic layer OL on the substrate SBT is smaller than the orthographic projection of the buffer layer BRR on the substrate SBT, so that a second surface SF2 is formed on the surface of the buffer layer BRR away from the substrate SBT, and the step difference between the adjacent two second surfaces SF2 and the first surface SF1 is not greater than the thickness of three organic layers OL.

[0067] In an example of the present disclosure, the number of organic layers OL of the display panel PNL is not less than 4. For example, the number of organic layers OL of the display panel PNL is 4. For another example, the number of organic layers OL of the display panel PNL is 5. For another example, the number of organic layers OL of the display panel PNL is 6. For another example, the number of organic layers OL of the display panel PNL is 7. For another example, the number of organic layers OL of the display panel PNL is 8. Of course, in other examples, the number of organic layers OL of the display panel PNL may also be other unshown numbers.

[0068] In an embodiment of the present disclosure, the display panel PNL has a plurality of organic layer groups, and each organic layer group has at least one organic layer OL. Hereinafter, taking the number of organic layers OL of the display panel PNL as 6 as an example, the optimization of the edge structure of the organic layer OL will be explained. In this example, the display panel PNL includes a first organic layer OL1, a second organic layer OL2, a third organic layer OL3, a fourth organic layer OL4, a fifth organic layer OL5, and a sixth organic layer OL6, which are sequentially arranged along the direction away from the substrate SBT. In this example, the organic layer OL is a planarization layer PLN.

[0069] In one example, referring to Figure 3 , the display panel PNL has three organic layer groups, and each organic layer group includes two organic layers OL. Among them, the first organic layer group includes the first organic layer OL1 and the second organic layer OL2, the second organic layer group includes the third organic layer OL3 and the fourth organic layer OL4, and the third organic layer group includes the fifth organic layer OL5 and the sixth organic layer OL6. In this example, the edges of the two organic layers OL within the same organic layer group are flush to form a first edge EG1, and the three first edges EG1 formed in the three organic layer groups are staggered along the first direction H1. It can be understood that along the direction away from the substrate SBT, each first edge EG1 gradually approaches the center of the display panel PNL, thereby forming a stepped structure at the edges of each organic layer OL. Among them, the height of the first edge EG1 is the thickness of two organic layers OL. It can be understood that a first surface SF1 is formed between two adjacent first edges EG1, and a first surface SF1 is also formed on the surface of the organic layer OL above the uppermost organic layer group. In addition, a second surface SF2 is formed at the buffer layer BRR. The step difference between two adjacent first surfaces SF1 and between the first surface SF1 and the second surface SF2 is the thickness of two organic layers OL. In the present disclosure, by forming a group with two adjacent organic layers and making each edge gradually approach the center of the display panel PNL, a stepped structure is formed at the edges of the plurality of organic layers OL in the display panel PNL, which can reduce the step difference of each step and lower the probability of wrinkles.

[0070] In another example, referring to Figure 4, the display panel PNL has six organic layer groups, and each organic layer group includes an organic layer OL. It can be understood that the edge of each organic layer OL is the first edge EG1 of each organic layer group, and the six first edges EG1 formed in the six organic layer groups are staggered along the first direction H1. It can be understood that along the direction away from the substrate SBT, each first edge EG1 gradually approaches the center of the display panel PNL, so as to form a stepped structure at the edge of each organic layer OL, where the height of the first edge EG1 is the thickness of an organic layer OL. It can be understood that a first surface SF1 is formed between adjacent first edges EG1, and a first surface SF1 is also formed on the surface of the uppermost organic layer OL, and a second surface SF2 is formed at the buffer layer BRR. The step difference between adjacent two first surfaces SF1 and between the first surface SF1 and the second surface SF2 is the thickness of an organic layer OL. In the present disclosure, the first edge EG1 of each organic layer OL is set to gradually approach the center of the display panel PNL, so that each organic layer OL forms a stepped structure at the edge of the display panel PNL, and further the step difference of each step can be reduced, and the probability of wrinkles appearing can be reduced.

[0071] In another example, refer to Figure 5, the display panel PNL has two organic layer groups (defined as the first organic layer group and the second organic layer group), each organic layer group includes three organic layers OL. The first organic layer group includes the first organic layer OL1, the second organic layer OL2, and the third organic layer OL3. The second organic layer group includes the fourth organic layer OL4, the fifth organic layer OL5, and the sixth organic layer OL6. In the first organic layer group, the thickness of the second organic layer OL2 gradually decreases along the direction away from the center of the display panel PNL to form a first inclined surface QX1, and the orthographic projection of the first inclined surface QX1 on the substrate SBT overlaps with the orthographic projection of the first organic layer OL1 located below it on the substrate SBT. The edge of the third organic layer OL3 located above it is flush with the second side edge of the first inclined surface QX1, and a second inclined surface QX2 is formed at the first inclined surface QX1. In the second organic layer group, the edge of the fifth organic layer OL5 is flush with the edge of the fourth organic layer OL4. The sixth organic layer OL6 covers the fifth organic layer OL5 and the fourth organic layer OL4 located below it, and covers the second inclined surface QX2. The sixth organic layer OL6 forms a step structure at the same height on the side of the fourth organic layer OL4 close to the substrate SBT. The first side surface of the step structure close to the center of the display panel PNL forms the first edge EG1 of the second organic layer group. The second side surface of the step structure away from the center of the display panel PNL is flush with the edge of the third organic layer OL3 of the lower organic layer group, forming the first edge EG1 of the first organic layer group. Thus, the height of the first edge EG1 of the second organic layer group is the thickness of three organic layers OL, and the height of the first edge EG1 of the first organic layer group is the height of three organic layers OL. It can be understood that the orthographic projection of the second organic layer OL2 on the substrate SBT covers the orthographic projection of the first organic layer OL1 on the substrate SBT, and the orthographic projection area of the second organic layer OL2 on the substrate SBT is larger than the orthographic projection area of the first organic layer OL1 on the substrate SBT. The second organic layer OL2 has a first inclined surface QX1 at the edge position of the first organic layer OL1 (it can be understood that the second organic layer OL2 thins at the edge position of the first organic layer OL1, thus forming the first inclined surface QX1). Thus, the height of the edge of the second organic layer OL2 (the edge on the side of the first inclined surface QX1 away from the center of the display panel PNL) is less than the total thickness of the second organic layer OL2 and the first organic layer OL1. Further, the height of the edge of the second organic layer OL2 (the edge on the side of the first inclined surface QX1 away from the center of the display panel PNL) is equal to the thickness of one organic layer OL. The orthographic projection of the first inclined surface QX1 on the substrate SBT overlaps with the orthographic projection of the first organic layer OL1 on the substrate SBT (in other words, the edge of the first organic layer OL1 is within the orthographic projection of the first inclined surface QX1 on the substrate SBT). The edge of the third organic layer OL3 is flush with the edge of the second organic layer OL2, and...The third organic layer OL3 has a second inclined surface QX2 at the first inclined surface QX1. The edge of the fourth organic layer OL4 is flush with the edge of the fifth organic layer OL5 and is simultaneously flush with the edge of the second inclined surface QX2 closer to the center of the display panel PNL. The orthographic projection area of the fourth organic layer OL4 on the substrate SBT is smaller than the orthographic projection area of the first organic layer OL1 on the substrate SBT. The orthographic projection of the sixth organic layer OL6 on the display panel PNL covers the orthographic projections of the respective organic layers OL (the first organic layer OL1, the second organic layer OL2, the third organic layer OL3, the fourth organic layer OL4, the fifth organic layer OL5) located below it on the display panel PNL. At the same time, the orthographic projection of the sixth organic layer OL6 on the display panel PNL is equal to the orthographic projection of the second organic layer OL2 located below it on the display panel PNL. The sixth organic layer OL6 has a stepped structure on the side away from the center of the display panel PNL (the sixth organic layer OL6 has a stepped structure in the first boundary region BOR1). The stepped surface of this stepped structure forms a first surface SF1, and the edge of this stepped surface away from the center of the display panel PNL is flush with the first edge EG1 of the second organic layer OL2. The side of the sixth organic layer OL6 away from the substrate SBT forms a first surface SF1. The step difference between the two first surfaces SF1 is the thickness of 3 organic layers OL, and the step difference between the first surface SF1 and the second surface SF2 is the thickness of 3 organic layers OL. In the present disclosure, by thinning the second organic layer OL2 at the edge of the first organic layer OL1 to form an inclined surface, a gentle step difference can be further formed, reducing the probability of wrinkles appearing.

[0072] In another example, refer to Figure 6, the display panel PNL has two organic layer groups, and the number of organic layers in the two organic layer groups is different. The number of organic layers OL in the first organic layer group is four, and the number of organic layers OL in the second organic layer group is two. It can be understood that the first organic layer group includes a first organic layer OL1, a second organic layer OL2, a third organic layer OL3, and a fourth organic layer OL4, and the second organic layer group includes a fifth organic layer OL5 and a sixth organic layer OL6. In the first organic layer group, the thickness of the second organic layer OL2 gradually decreases along the direction away from the center of the display panel PNL to form a first inclined surface QX1, and the orthographic projection of the first inclined surface QX1 on the substrate SBT overlaps with the orthographic projection of the first organic layer OL1 located below it on the substrate SBT. The edges of the third organic layer OL3 and the fourth organic layer OL4 located above it are flush with the second side edge (the side away from the center of the display panel PNL) of the first inclined surface QX1, forming a first edge EG1 of the first organic layer group. The third organic layer OL3 and the fourth organic layer OL4 form a second inclined surface QX2 at the first inclined surface QX1. In the second organic layer group, the edges of each organic layer OL are flush to form a first edge EG1. It can be understood that the edges of the fifth organic layer OL5 and the sixth organic layer OL6 are flush to form a first edge EG1. In this example, the height of the first edge EG1 of the first organic layer group is the thickness of three organic layers OL, and the height of the first edge EG1 in the second organic layer group is the thickness of two organic layers OL. Adopting this solution reduces the thickness of one organic layer OL in the removal area QC of the display panel PNL. In other words, the orthographic projection of the second organic layer OL2 on the substrate SBT covers the orthographic projection of the first organic layer OL1 on the substrate SBT, and the orthographic projection area of the second organic layer OL2 on the substrate SBT is larger than the orthographic projection area of the first organic layer OL1 on the substrate SBT. The second organic layer OL2 has a first inclined surface QX1 at the edge position of the first organic layer OL1 (it can be understood that the second organic layer OL2 is thinned at the edge position of the first organic layer OL1 to form the first inclined surface QX1), so that the height of the edge of the second organic layer OL2 (the edge of the first inclined surface QX1 away from the center of the display panel PNL) is less than the total thickness of the second organic layer OL2 and the first organic layer OL1. For example, the height of the edge of the second organic layer OL2 (the edge of the first inclined surface QX1 away from the center of the display panel PNL) is equal to the thickness of one organic layer. The orthographic projection of the first inclined surface QX1 on the substrate SBT overlaps with the orthographic projection of the first organic layer OL1 on the substrate SBT (in other words, the edge of the first organic layer OL1 is within the orthographic projection of the first inclined surface QX1 on the substrate SBT). The edges of the third organic layer OL3 and the fourth organic layer OL4 are flush with the edge of the second organic layer OL2, thus forming a first edge EG1 of the first organic layer group.The third organic layer OL3 and the fourth organic layer OL4 form a second inclined surface QX2 at the first inclined surface QX1. The edge of the fifth organic layer OL5 is flush with the edge of the sixth organic layer OL6, and at the same time is flush with the edge of the second inclined surface QX2 on the side closer to the center of the display panel PNL. The second inclined surface QX2 is the first surface SF1. The height of the first edge EG1 formed by the first organic layer group is the thickness of three organic layers OL, and the height of the first edge EG1 formed by the second organic layer group is the thickness of two organic layers OL. In the present disclosure, the first inclined surface QX1 is formed by thinning the second organic layer OL2 at the edge of the first organic layer OL1, reducing the thickness of one organic layer OL, which can further reduce the step difference and the probability of wrinkles.

[0073] In another embodiment of the present disclosure, referring to Figure 7 , the number of organic layers OL in the removal area QC can be reduced. In this way, the thickness of the organic layers OL in the removal area QC can be reduced. For example, the fourth organic layer OL4 and the fifth organic layer OL5 can only extend to the edge of the panel area NL (it can be understood that the fourth organic layer OL4 and the fifth organic layer OL5 only extend to the boundary between the cutting area NLB and the removal area QC). In this example, the number of organic layers OL in each organic layer group is the same, and each organic layer group includes three organic layers OL. It can be understood that the first organic layer group includes the first organic layer OL1, the second organic layer OL2, and the third organic layer OL3, and the second organic layer group includes the fourth organic layer OL4, the fifth organic layer OL5, and the sixth organic layer OL6.

[0074] In the first organic layer group, the second organic layer OL2 covers the organic layer OL located therebelow, and forms an edge with a thickness of two organic layers OL at the first boundary region BOR1. The edge of the third organic layer OL3 located thereabove is flush with the edge of the organic layer OL in the middle, thereby forming the first edge EG1 of the first organic layer group; the height of the first edge EG1 is the thickness of three organic layers OL. In the second organic layer group, the fourth organic layer OL4 and the fifth organic layer OL5 only extend to the cutting region NLB; the edge of the sixth organic layer OL6 forms the first edge EG1 of the second organic layer group, and the first edge EG1 of the second organic layer group is located on the side closer to the center of the display panel PNL of the first edge EG1 of the first organic layer group. It can be understood that the orthographic projection of the second organic layer OL2 on the substrate SBT covers the orthographic projection of the first organic layer OL1 on the substrate SBT and the orthographic projection of the second organic layer OL2 on the substrate SBT is larger than the orthographic projection of the first organic layer OL1 on the substrate SBT. The edge of the third organic layer OL3 is flush with the edge of the second organic layer OL2 to form the first edge EG1, the edge of the sixth organic layer OL6 forms the first edge EG1, and a first surface SF1 is formed between the two first edges EG1. The height of the first edge EG1 is the thickness of three organic layers OL.

[0075] Of course, in other examples of the present disclosure, each organic layer OL may also adopt other methods to reduce the step difference.

[0076] In one embodiment of the present disclosure, the horizontal width of the first surface SF1 is not less than 300 microns. In this way, the staggering between two adjacent first edges EG1 can be ensured, and the stability of the stepped structure can be ensured.

[0077] In one example of the present disclosure, all the organic layers OL are planarization layers. In another example of the present disclosure, some of the organic layers OL may be planarization layers, and some of the organic layers OL may be passivation layers. Of course, in other examples, the organic layer OL may be other film layers.

[0078] In one example of the present disclosure, the display panel PNL further includes a pixel layer PIXL located on the side of the driving layer DRL away from the substrate SBT. The pixel layer PIXL may be provided with sub-pixels, and a pixel driving circuit is used to drive the sub-pixels to emit light. In some embodiments, the pixel layer PIXL may be provided with a light-emitting element LD electrically connected to the pixel driving circuit correspondingly, and the light-emitting element LD may be used as a sub-pixel of the display panel PNL.

[0079] Exemplarily, the pixel layer PIXL is provided with light-emitting elements LD arranged in an array, and each light-emitting element LD emits light under the control of a pixel driving circuit. In the present disclosure, the light-emitting element LD can be an organic light-emitting diode (OLED), a micro light-emitting diode (Micro LED), a quantum dot-organic light-emitting diode (QD-OLED), a quantum dot light-emitting diode (QLED), or other types of light-emitting elements LD. Exemplarily, in an embodiment of the present disclosure, if the light-emitting element LD is an organic light-emitting diode (OLED), then the display panel PNL is an OLED display panel PNL. As follows, taking the light-emitting element LD as an organic light-emitting diode as an example, a feasible structure of the pixel layer PIXL will be introduced exemplarily.

[0080] Optionally, the pixel layer PIXL can be disposed on a side of the driving layer DRL away from the organic substrate SBT, and it can include a pixel electrode layer PEL, a pixel definition layer PDL, a support pillar layer PSC, an organic light-emitting functional layer EFL, and a common electrode layer COML that are sequentially stacked. Among them, the pixel electrode layer PEL has a plurality of pixel electrodes in the display area of the sub-panel; the pixel definition layer PDL has a plurality of through pixel openings corresponding one-to-one with the plurality of pixel electrodes in the display area, and any one pixel opening exposes at least a partial area of the corresponding pixel electrode. The support pillar layer includes a plurality of support pillars PS in the display area, and the support pillars PS are located on a surface of the pixel definition layer PDL away from the organic substrate SBT to support a fine metal mask (FMM) during the evaporation process. The organic light-emitting functional layer EFL covers at least the pixel electrode exposed by the pixel definition layer PDL. Among them, the organic light-emitting functional layer EFL can include an organic light-emitting material layer, and can include one or more of a hole injection layer, a hole transport layer, an electron blocking layer, a hole blocking layer, an electron transport layer, and an electron injection layer. Each film layer of the organic light-emitting functional layer EFL can be prepared by an evaporation process, and a fine metal mask or an open mask can be used to define the pattern of each film layer during evaporation. The common electrode layer COML can cover the organic light-emitting functional layer EFL in the display area. In this way, the pixel electrode, the common electrode layer COML, and the organic light-emitting functional layer EFL located between the pixel electrode and the common electrode layer COML form an organic light-emitting diode, that is, the light-emitting element LD, and any one organic light-emitting diode can be used as a sub-pixel of the display panel PNL.

[0081] In an embodiment of the present disclosure, the organic layer can include the pixel definition layer PDL.

[0082] Optionally, in subsequent processes, the display panel PNL may further include a thin film encapsulation layer TFE. The thin film encapsulation layer TFE is disposed on the surface of the pixel layer PIXL away from the organic substrate SBT, and may include an inorganic encapsulation layer and an organic encapsulation layer alternately stacked. Among them, the inorganic encapsulation layer can effectively block external moisture and oxygen, avoiding the invasion of water and oxygen into the organic light-emitting functional layer EFL and causing material degradation. Optionally, the edge of the inorganic encapsulation layer may be located in the peripheral area of the sub-panel. The organic encapsulation layer is located between two adjacent inorganic encapsulation layers to achieve planarization and reduce the stress between the inorganic encapsulation layers. Among them, the edge of the organic encapsulation layer may be located between the edge of the display area and the edge of the inorganic encapsulation layer. Exemplarily, the thin film encapsulation layer TFE includes a first inorganic encapsulation layer, an organic encapsulation layer, and a second inorganic encapsulation layer sequentially stacked on the side of the pixel layer PIXL away from the organic substrate SBT.

[0083] In an embodiment of the present disclosure, referring to Figure 8 , the display panel PNL may further include a substrate support layer JQ located on the side of the substrate SBT away from the driving layer.

[0084] Those skilled in the art will readily conceive of other embodiments of the present disclosure after considering the specification and practicing the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of the present disclosure, which follow the general principles of the present disclosure and include known common knowledge or conventional technical means in the technical field not disclosed by the present disclosure. The specification and examples are only regarded as exemplary, and the true scope and spirit of the present disclosure are pointed out by the appended claims.

Claims

1. A display panel, characterized in that: It includes a base substrate and a plurality of organic layer groups sequentially stacked on the base substrate, each of the organic layer groups including at least one organic layer; The display panel has a first boundary region, at least part of the organic layer group forms a plurality of first edges staggered along a first direction in the first boundary region, and the height of the first edges is not greater than the thickness of the three organic layers; The display panel further includes a first protective film, and the first protective film covers the first boundary area.

2. The display panel according to claim 1, characterized in that: A first surface is formed between at least a portion of the organic layers in the first boundary region, and a second surface is formed between at least a portion of the organic layers and the base substrate in the first boundary region; The step difference between two adjacent first surfaces and between the adjacent first surface and the second surface is not greater than the thickness of three organic layers.

3. The display panel according to claim 1, characterized in that: The display panel has a panel area and a removal area; the first boundary area is located in the removal area.

4. The display panel according to claim 1, characterized in that: The total number of the organic layers is not less than 4.

5. The display panel according to claim 1, characterized in that: Each organic layer group includes two organic layers arranged adjacent to each other; the edges of the two organic layers in the same organic layer group are aligned to form the first edge; Along a direction away from the base substrate, each of the first edges gradually approaches the center of the display panel.

6. The display panel according to claim 1, characterized in that: Each organic layer group includes one organic layer; the edge of each organic layer is the first edge; Along a direction away from the base substrate, each of the first edges gradually approaches the center of the display panel.

7. The display panel according to claim 3, characterized in that: The number of organic layers in the organic layer groups is the same, and each organic layer group includes three organic layers; In two adjacent organic layer groups, the thickness of the organic layer located in the middle of the lower organic layer group gradually decreases along the direction away from the center of the display panel to form a first inclined surface, and the orthographic projection of the first inclined surface on the base substrate partially overlaps with the orthographic projection of the organic layer located below it on the base substrate, and the edge of the organic layer located above it is flush with the second side edge of the first inclined surface, forming a second inclined surface and a first edge of the organic layer group; In the upper organic layer group, the organic layer away from the base substrate covers all the organic layers below it and covers the second inclined surface. The organic layer located above forms a step structure at the same height as the first side of the second inclined surface. The first side of the step structure forms a first edge, and the second side of the step structure is flush with the first edge of the organic layer group below.

8. The display panel according to claim 3, characterized in that: In two adjacent organic layer groups, the number of organic layers in the lower organic layer group is four, and the number of organic layers in the upper organic layer group is two; The thickness of the organic layer located in the middle of the lower organic layer group gradually decreases along the direction away from the center of the display panel to form a first inclined surface, and the orthographic projection of the first inclined surface on the base substrate partially overlaps with the orthographic projection of the organic layer located below it on the base substrate, and the edge of the organic layer located above it is flush with the second side edge of the first inclined surface, forming a second inclined surface and a first edge of the organic layer group; In the upper organic layer group, the edges of the organic layers are aligned to form a first edge.

9. The display panel according to claim 2, characterized in that: The display panel comprises a panel area and a removal area; The panel area has a plurality of sub-panel areas and a cutting area surrounding each of the sub-panel areas, wherein a portion of the organic layer only extends to the cutting area.

10. The display panel according to claim 9, characterized in that: The number of organic layers in the organic layer groups is the same, and each organic layer group includes three organic layers; In the lower organic layer group, the organic layer located in the middle covers the organic layer located below it, and the edge of the organic layer located above it is flush with the edge of the organic layer located in the middle, forming a first edge; In the upper organic layer group, the lower part of the organic layer only extends to the cutting area; the edge of the organic layer located above forms a first edge, and the first edge of the upper organic layer group is located on the side of the first edge of the first organic layer group close to the center of the display panel.

11. The display panel according to any one of claims 3 to 10, characterized in that: The horizontal distance between two adjacent first edges is not less than 300 micrometers.

12. The display panel according to claim 11, characterized in that: The organic layer includes a planarization layer.

13. A method for preparing a display panel, characterized in that: include: Forming a display panel as described in any one of claims 1-12.

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