Manufacturing method of display panel, mask plate and display panel
By using electrically charged gel particles to control the selective passage of luminescent materials in OLED display panels, the problem of repeatedly replacing photomasks was solved, resulting in cost savings and improved alignment accuracy.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- HKC CORP LTD
- Filing Date
- 2026-01-21
- Publication Date
- 2026-05-15
AI Technical Summary
In OLED display panels, existing technology requires multiple mask replacements to form light-emitting units of different colors, resulting in high costs and a high risk of alignment defects.
By encapsulating luminescent materials with electrically charged gel particles and controlling their selective passage through the channels of a photomask using an external electric field, different colored luminescent units are formed, avoiding the need for multiple photomask movements.
This reduces the production cost of display panels, improves product quality, and reduces the possibility of misalignment.
Smart Images
Figure CN121568514B_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of display technology, and in particular to a display panel, a method for manufacturing the same, a photomask, and the display panel. Background Technology
[0002] In OLED (Organic Light-Emitting Diode) devices, the organic light-emitting unit (OLED) is the core component, which needs to be formed through a vapor deposition process. Different colored OLEDs require separate vapor deposition steps due to differences in materials, formation location, and size. Generally, the luminescent material of the OLED needs to be deposited using a photomask. The photomask is placed close to the substrate, and channels are created on the photomask to allow the luminescent material to pass through. Areas on the photomask without channels prevent the luminescent material from passing through, thus forming a patterned luminescent material.
[0003] One method involves moving a photomask to form light-emitting units of different colors, which can easily lead to misalignment defects. Furthermore, creating separate photomasks for each color of light-emitting unit is costly and requires photomask replacement, also resulting in misalignment defects. Summary of the Invention
[0004] The purpose of this application is to provide a method for manufacturing a display panel, a photomask, and a display panel. The method utilizes electrically charged gel to encapsulate light-emitting particles to form electrically charged gel particles. By controlling the electrically charged gel particles to selectively pass through the photomask through an external electric field, a patterned light-emitting material manufacturing process can be achieved, saving costs and improving product quality.
[0005] This application discloses a method for manufacturing a display panel, including the following steps:
[0006] Provide a substrate;
[0007] Luminescent material particles are combined with an aerogel polymer precursor to form multiple electrically charged gel particles; wherein, luminescent particles are encapsulated within the electrically charged gel particles.
[0008] Multiple charged aerogel particles are emitted into multiple channels inside the mask.
[0009] After the multiple charged aerogel particles collapse within the channel, they release multiple light-emitting particles, which respectively form multiple light-emitting portions within multiple opening areas of the substrate.
[0010] Multiple light-emitting units are formed on the substrate.
[0011] The number of the plurality of channels is the same as the number of the plurality of opening regions.
[0012] Optionally, the step of forming a plurality of electrically charged gel particles from luminescent material particles and an aerogel polymer precursor includes:
[0013] Multiple red luminescent material particles are combined with an aerogel polymer precursor to form multiple red electrically charged gel particles;
[0014] Multiple green luminescent material particles are combined with an aerogel polymer precursor to form multiple green electrified gel particles;
[0015] Multiple blue luminescent material particles are combined with an aerogel polymer precursor to form multiple blue electrically charged gel particles;
[0016] The step of emitting the plurality of charged aerogel particles into the plurality of channels inside the mask includes:
[0017] Multiple red-banded electrically conductive gel particles are emitted into multiple first channels inside the mask.
[0018] Multiple green-banded electrogel particles are emitted into multiple second channels inside the mask;
[0019] Multiple blue electrically charged gel particles are emitted into multiple third channels inside a mask; wherein the multiple channels include multiple first channels, multiple second channels, and multiple third channels.
[0020] Optionally, the step of releasing multiple light-emitting particles after the plurality of charged aerogel particles collapse within the channel, and forming multiple light-emitting portions in multiple opening regions of the substrate by the multiple light-emitting particles respectively, includes:
[0021] A high-frequency mechanical wave is used to cause a physical change in the multiple red electrically charged gel particles in the first channel, releasing multiple red luminescent particles. The multiple red luminescent particles form multiple red luminescent parts in multiple first opening regions.
[0022] High-frequency mechanical waves are used to cause multiple green electrically conductive gel particles in the second channel to collapse and release multiple green luminescent particles, which then form multiple green luminescent portions in multiple second opening regions.
[0023] A high-frequency mechanical wave is used to cause a physical change in the multiple red electrically charged gel particles in the third channel, which then releases multiple green luminescent particles. The multiple blue luminescent particles form multiple blue luminescent portions in the multiple third opening regions.
[0024] The plurality of opening regions include a plurality of first opening regions, a plurality of second opening regions, and a plurality of third opening regions.
[0025] Optionally, the step of emitting the plurality of red-banded electrically conductive gel particles into the plurality of first channels inside the mask includes:
[0026] An electric field is applied to the second and third channels to prevent the red-banded electrogel particles from entering;
[0027] Multiple red electrically charged gel particles are launched onto a photomask using a high-speed airflow.
[0028] Multiple red electrically charged gel particles enter multiple first channels inside the mask;
[0029] The step of emitting a plurality of the green charged gel particles into a plurality of second channels inside a mask includes:
[0030] An electric field is applied to the first and third channels to prevent the green-banded electrogel particles from entering;
[0031] Multiple green electrically charged gel particles are emitted onto a photomask using a high-speed airflow.
[0032] Multiple green-banded electrogel particles enter multiple second channels inside the mask;
[0033] The step of emitting a plurality of the blue electrically charged gel particles into a plurality of third channels inside a mask includes:
[0034] An electric field is applied to the first and second channels to prevent the blue-banded electrogel particles from entering;
[0035] Multiple blue electrically charged gel particles are emitted onto a photomask using a high-speed gas flow.
[0036] Multiple blue-banded electrogel particles enter multiple third channels inside the mask.
[0037] This application also discloses a method for manufacturing a display panel, including the following steps:
[0038] Provide a substrate;
[0039] Multiple red luminescent material particles are combined with an aerogel polymer precursor to form multiple red electrically charged gel particles; multiple green luminescent material particles are combined with an aerogel polymer precursor to form multiple green electrically charged gel particles; and multiple blue luminescent material particles are combined with an aerogel polymer precursor to form multiple blue electrically charged gel particles.
[0040] An electric field is applied to the second and third channels to prevent the red charged gel particles from entering. Multiple red charged gel particles are emitted into multiple first channels inside the mask. A high-frequency mechanical wave is used to cause a physical change in the multiple red charged gel particles in the first channels, releasing multiple red light-emitting particles. Multiple red light-emitting particles form multiple red light-emitting parts in multiple first opening areas.
[0041] An electric field is applied to the first and third channels to prevent the green charged gel particles from entering. Multiple green charged gel particles are emitted into multiple second channels inside the mask. High-frequency mechanical waves are used to cause the multiple green charged gel particles in the second channels to collapse and release multiple green light-emitting particles. Multiple green light-emitting particles form multiple green light-emitting parts in multiple second opening areas.
[0042] An electric field is applied to the first and second channels to prevent the blue charged gel particles from entering. Multiple blue charged gel particles are emitted into multiple third channels inside the mask. A high-frequency mechanical wave is used to cause multiple red charged gel particles in the third channels to undergo physical changes and release multiple blue luminescent particles. Multiple blue luminescent particles form multiple blue luminescent parts in multiple third opening areas.
[0043] This forms multiple red light-emitting units, multiple green light-emitting units, and multiple blue light-emitting units;
[0044] The mask is provided with multiple first channels, multiple second channels and multiple third channels, and the substrate is provided with multiple first opening regions, multiple second opening regions and multiple third opening regions; the first channels are provided corresponding to the first opening regions, the second channels are provided corresponding to the second opening regions, and the third channels are provided corresponding to the third opening regions.
[0045] This application discloses a photomask for the above-mentioned method of manufacturing a display panel. The photomask includes a photomask body and a plurality of channels disposed on the photomask body. The plurality of channels include a plurality of first channels, a plurality of second channels, and a plurality of third channels. A first control electrode is disposed in the first channel, a second control electrode is disposed in the second channel, and a third control electrode is disposed in the third channel. The plurality of first control electrodes are electrically connected to each other, the plurality of second control electrodes are electrically connected to each other, and the plurality of third control electrodes are electrically connected to each other.
[0046] Optionally, the first control electrode is located in the middle of the first channel, the second control electrode is located in the middle of the second channel, and the third control electrode is located in the middle of the third channel; wherein the opening areas of the first channel, the second channel, and the third channel are different.
[0047] This application discloses a display panel formed by the above-described display panel manufacturing method. The display panel includes a substrate, a pixel definition layer disposed on the substrate, and a plurality of light-emitting units. The pixel definition layer has a plurality of openings to form a plurality of opening regions. The plurality of light-emitting units are respectively disposed in the plurality of opening regions, and adjacent light-emitting units are separated by the pixel definition layer. The light-emitting unit includes a bottom electrode, a light-emitting part, and a top electrode. The light-emitting part is disposed between the bottom electrode and the top electrode. The pixel definition layer includes a bottom and an upper part. The upper part is disposed on the side of the bottom away from the substrate. The radial width of the upper part is smaller than the radial width of the bottom.
[0048] Optionally, the bottom electrode has an arc surface on the side away from the substrate, and the thickness of the bottom electrode gradually decreases from the centerline to the surrounding area; wherein, the plurality of light-emitting units include a plurality of red light-emitting units, a plurality of green light-emitting units, and a plurality of blue light-emitting units; the plurality of opening regions include a plurality of first opening regions, a plurality of second opening regions, and a plurality of third opening regions; the red light-emitting units are located in the first opening regions, the green light-emitting units are located in the second opening regions, and the blue light-emitting units are located in the third opening regions.
[0049] Optionally, the bottom electrode includes a reflective metal layer and a transparent electrode layer. The transparent electrode layer is disposed on the side of the reflective metal layer away from the substrate, and the thickness of the transparent electrode layer gradually decreases from the centerline of the bottom electrode outwards.
[0050] In this application, electrically charged gel particles are formed by encapsulating light-emitting particles with electrically charged gel, thus imbuing each particle with electrical properties. An external electric field is used to control the selective passage of these particles through multiple channels of a photomask. This allows for the formation of multiple light-emitting units in stages without moving the photomask, by controlling the passage of particles through channels at different locations. This achieves a patterned light-emitting material fabrication process. Comparatively, this application eliminates the need for multiple photomasks to accommodate light-emitting units at different locations, saving the cost of manufacturing three photomasks and reducing the overall production cost of the display panel, thus enhancing product competitiveness. Furthermore, it eliminates the need to move the same photomask multiple times to create light-emitting units at different positions. This avoids multiple photomask movements, saving alignment steps, reducing the possibility of misalignment, and improving the quality of the display panel. Attached Figure Description
[0051] The accompanying drawings, which form part of the specification, are used to provide a further understanding of the embodiments of this application and illustrate the implementation methods of this application, together with the textual description, to explain the principles of this application. Obviously, the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any creative effort. In the drawings:
[0052] Figure 1 This is a schematic diagram illustrating the steps of a method for manufacturing a display panel according to the first embodiment of this application;
[0053] Figure 2 This is a schematic diagram illustrating the steps of a second method for manufacturing a display panel according to the first embodiment of this application;
[0054] Figure 3 This is a process schematic diagram of the second type of display panel according to the first embodiment of this application;
[0055] Figure 4 This is a schematic diagram of a photomask used in this application;
[0056] Figure 5 This is a schematic diagram illustrating the steps of a method for manufacturing a display panel according to the second embodiment of this application;
[0057] Figure 6 This is a schematic diagram of the display panel of this application.
[0058] Among them, 100 is a display panel; 110 is a substrate; 111 is a pixel definition layer; 111a is a first opening area; 111b is a second opening area; 111c is a third opening area; 112 is an upper part; 113 is a bottom part; 120 is a light-emitting unit; 120R is a red light-emitting unit; 120G is a green light-emitting unit; 120B is a blue light-emitting unit; 121 is a bottom electrode; 1211 is a transparent electrode layer; 1212 is a reflective metal layer; 122 is a light-emitting part; 122R is a red light-emitting part; 122G is a green light-emitting part; 122B is a blue light-emitting part; 123 is a top electrode; 200 is a mask; 210 is a mask body; 220 is a first channel; 221 is a first control electrode; 230 is a second channel; 231 is a second control electrode; 240 is a third channel; 241 is a third control electrode. Detailed Implementation
[0059] It should be understood that the terminology, specific structural and functional details used herein are merely for describing particular embodiments and are representative. However, this application may be implemented in many alternative forms and should not be construed as being limited to the embodiments set forth herein.
[0060] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating relative importance or implying the number of technical features indicated. Therefore, unless otherwise stated, a feature specified as "first" or "second" may explicitly or implicitly include one or more of that feature; "multiple" means two or more. Furthermore, terms such as "upper," "lower," "left," "right," "vertical," and "horizontal," indicating orientation or positional relationships, are based on the orientation or relative positional relationships shown in the accompanying drawings and are only for the purpose of simplifying the description of this application, not indicating that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting this application. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.
[0061] The present application will now be described in detail with reference to the accompanying drawings and optional embodiments.
[0062] Figure 1 This is a schematic diagram illustrating the steps of a method for manufacturing a display panel according to the first embodiment of this application. See also... Figure 1 As shown, this application discloses a method for manufacturing a display panel, including the following steps:
[0063] S10: Provides a substrate;
[0064] S20: Luminescent material particles are combined with an aerogel polymer precursor to form multiple electrically charged gel particles, wherein the electrically charged gel particles encapsulate luminescent particles.
[0065] S30: Emitting multiple charged aerogel particles into multiple channels inside the mask;
[0066] S40: After the multiple charged aerogel particles undergo physical changes in the channel, they release multiple light-emitting particles, and the multiple light-emitting particles respectively form multiple light-emitting parts in multiple opening areas of the substrate.
[0067] S50: A plurality of light-emitting units are formed on the substrate;
[0068] The number of the plurality of channels is the same as the number of the plurality of opening regions.
[0069] In this application, electrically charged gel particles are formed by encapsulating light-emitting particles with electrically charged gel, thus imbuing each particle with electrical properties. An external electric field is used to control the selective passage of these particles through multiple channels of a photomask. This allows for the formation of multiple light-emitting units in stages without moving the photomask, by controlling the passage of particles through channels at different locations. This achieves a patterned light-emitting material fabrication process. Comparatively, this application eliminates the need for multiple photomasks to accommodate light-emitting units at different locations, saving the cost of manufacturing three photomasks and reducing the overall production cost of the display panel, thus enhancing product competitiveness. Furthermore, it eliminates the need to move the same photomask multiple times to create light-emitting units at different positions. This avoids multiple photomask movements, saving alignment steps, reducing the possibility of misalignment, and improving the quality of the display panel.
[0070] Taking a display panel with three primary colors as an example, a pixel typically has three sub-pixels, composed of red, green, and blue light-emitting units respectively. Each color of light-emitting unit corresponds to a sub-pixel of that color, such as red, green, and blue sub-pixels. Based on the area of the three sub-pixels within a pixel, display panels can be divided into those with equal sub-pixel areas and those with unequal sub-pixel areas.
[0071] For display panels with equal sub-pixel areas, a single mask can be used to form the light-emitting parts of each light-emitting unit. This means multiple channels are formed on the mask, the number of which is equal to one-third the number of sub-pixels. These channels correspond to multiple red sub-pixels, multiple green sub-pixels, or multiple blue sub-pixels. In the process, red light-emitting units are first formed using the mask. Then, the mask is moved so that the channels correspond to the green sub-pixel areas, forming green light-emitting units. The mask is moved again so that the channels correspond to the blue sub-pixel areas, forming blue light-emitting units. This process is repeated three times to form red, green, and blue light-emitting units respectively. Three alignment processes are required to align the channels on the mask with the sub-pixel areas. However, when the sub-pixel areas of the display panel are unequal, the mask cannot be moved twice to create light-emitting units of different colors.
[0072] For display panels with subpixel areas of varying sizes, separate masks are typically required for subpixels of different colors. For example, a red pixel mask with a channel the size of the red subpixel arrangement is used for the red subpixel position. Similarly, a green pixel mask is used for green subpixels, and a blue pixel mask is used for blue subpixels. In the fabrication process of the light-emitting unit, the red pixel mask is used to form the red light-emitting unit, and then removed after completion. The green pixel mask is moved above the substrate, aligned, and then used to form the green light-emitting unit, which is then removed after the process is complete. The blue pixel mask is moved above the substrate, aligned, and then used to form the blue light-emitting unit, which is finally removed. This process requires not only three alignment steps but also three masks, increasing both cost and processing time, thus increasing the cost of the display panel.
[0073] It is understood that the channels of the mask in this application can correspond to red, green, and blue sub-pixels. Charged gel particles are formed by encapsulating luminescent material within an electrically charged gel. After drying, these particles are delivered to the mask using an inert gas flow. When a red luminescent unit needs to be formed, the channel corresponding to the red sub-pixel is kept without an electric field, allowing the charged gel particles to pass through. Conversely, the channels corresponding to the green and blue sub-pixels are kept with an electric field, preventing the charged gel particles from passing through. This achieves the formation of a luminescent portion only at the red sub-pixel location. Similarly, luminescent portions of corresponding colors are formed in two separate steps at the green and blue sub-pixels.
[0074] Specifically, steps S20 include:
[0075] S21: Multiple red luminescent material particles are combined with an aerogel polymer precursor to form multiple red electrically charged gel particles;
[0076] S22: Multiple green luminescent material particles are combined with an aerogel polymer precursor to form multiple green electrified gel particles;
[0077] S23: Multiple blue luminescent material particles are combined with an aerogel polymer precursor to form multiple blue electrified gel particles.
[0078] In this embodiment, charged gel materials are used to encapsulate light-emitting particles of different colors in steps, thereby forming red, green, and blue charged gel particles, respectively. The three types of charged gel particles are stored in different evaporation sources, and in subsequent processes, the charged gel particles of different colors are sprayed onto a photomask and a substrate, respectively.
[0079] Aerogels are nanoscale porous solid materials formed by the molten gel method, in which gas replaces the liquid phase in the gel through a specific drying process. By selecting specific raw materials or introducing charged functional groups during / after synthesis, the charge properties of aerogels can be precisely controlled, thereby achieving positive or negative charge.
[0080] The electrical properties of aerogels primarily stem from their large specific surface area and surface chemical properties. The generation of charge occurs in several ways. First, intrinsic charge: aerogel materials, such as silica, ionize or adsorb ions in solution, thus becoming charged. For example, the numerous silanol groups (-Si-OH) on the surface of silica aerogel dissociate in water according to pH, generating a negative charge (-Si-O-). Second, functionalization modification: chemically grafting or introducing functional groups or molecules with permanent charges onto the aerogel's backbone network gives it a stable charge. For example, introducing quaternary ammonium groups (-N+R3) and amino groups (-NH2, which protonates to -NH3+ under acidic conditions) makes the aerogel positively charged. Introducing sulfonic acid groups (-SO3-) and carboxyl groups (-COOH, which ionizes to -COO-) makes the aerogel negatively charged. Third, composite materials formed by combining aerogels with inherently charged materials. For example, it can be combined with charged polymers, including negatively charged sodium polystyrene sulfonate (PSS) and positively charged polydiallyldimethylammonium chloride (PDADMAC) and other polyelectrolytes. It can also be combined with charged nanomaterials, such as graphene oxide, which has numerous carboxyl and hydroxyl groups on its surface and is negatively charged.
[0081] Taking the preparation of positively charged aerogels as an example, the main goal is to introduce positively charged groups. For example, in amino-modified silica aerogels, during the molten gelation process, amino-containing silane precursors (such as APTES: 3-aminopropyltriethoxysilane) are co-hydrolyzed and condensed with tetraethyl orthosilicate (TEOS). The resulting gel network contains a large number of -NH2 groups. In an acidic environment, these amino groups protonate (-NH3+), thus making the entire aerogel positively charged. Another example is quaternization modification: through subsequent chemical reactions, the amino groups in the gel are further quaternized to generate permanently positively charged quaternary ammonium salt groups (-N+R3), whose charge is unaffected by pH. Another example is polymer-based aerogels: aerogels are prepared directly using positively charged polymers (such as chitosan, whose amino groups are positively charged under acidic conditions) as raw materials. For example, composite magnetic positively charged gels: For example, Fe3O4 nanoparticles (which can be positively modified) are combined with positively charged polymers to prepare aerogels that are both positively charged and magnetic.
[0082] Taking the preparation of negatively charged aerogels as an example, the main goal is to introduce negatively charged groups. For instance, sulfonic acid-modified SiO2 aerogels are synthesized using silane coupling agents containing sulfonic acid groups. Carboxyl-modified SiO2 aerogels are synthesized using silane coupling agents containing carboxyl groups (such as carboxyethylsilane triol). Graphene oxide (GO) aerogels are another example; graphene oxide (GO) itself contains a large number of negatively charged groups (-COOH, -OH), and the aerogels assembled from it naturally possess strong negative charge. Cellulose nanofiber (CNF) aerogels are another example; cellulose nanofibers (CNF) contain carboxyl groups on their surface, and the aerogels prepared from them are also negatively charged. Finally, polymer-based aerogels are prepared using negatively charged polymers, such as sodium alginate (containing -COO-).
[0083] Specifically, by utilizing a reversible gel network, aerogels can encapsulate luminescent particles during formation and achieve controlled release under specific conditions. This encapsulation can be achieved through co-gelation, gelation, or supercritical drying. Co-gelation involves directly dispersing target solute particles in the aerogel precursor, such as dispersing drug powder or nanocatalysts in a silicon source (e.g., TEOS), cellulose solution, or polymer solution. Gelation involves adjusting temperature, pH, or adding a crosslinking agent to gel the sol system. During the formation of the three-dimensional network, solute particles are physically trapped in the network voids or structure. Supercritical drying involves subsequent supercritical drying (to avoid pore structure collapse) to obtain a composite aerogel encapsulating solute particles.
[0084] Specifically, step S30 includes the following steps:
[0085] S31: Emit multiple red-banded electrically conductive gel particles into multiple first channels inside the mask;
[0086] S32: Emit multiple green-banded electrogel particles into multiple second channels inside the mask;
[0087] S33: A plurality of the aforementioned blue electrically charged gel particles are emitted into a plurality of third channels within the mask. These plurality of channels include a plurality of first channels, a plurality of second channels, and a plurality of third channels.
[0088] After charging the red, green, and blue charged gel particles respectively, taking the red charged gel particles as an example, by setting an electric field, the red charged gel particles cannot pass through the second and third channels when forming the red light-emitting part, so that the red light-emitting part is formed only at the position corresponding to the first channel.
[0089] Figure 2 This is a schematic diagram illustrating the steps of a second method for manufacturing a display panel according to the first embodiment of this application. Figure 3 This is a process diagram of the second type of display panel according to the first embodiment of this application. See also Figures 2 to 3 As shown, step S31 includes:
[0090] S311: Apply an electric field to the second and third channels to prevent the red-banded electrically conductive gel particles from entering;
[0091] S312: A plurality of the red electrically charged gel particles are emitted onto a mask using a high-speed airflow;
[0092] S313: A plurality of the red-banded electrogel particles enter a plurality of the first channels inside the mask.
[0093] The steps in S32 include:
[0094] S321: Apply an electric field to the first channel and the third channel to prevent the green-banded electrogel particles from entering;
[0095] S322: A plurality of the green electrified gel particles are emitted onto a mask using a high-speed airflow;
[0096] S323: A plurality of the green-banded electrogel particles enter a plurality of the second channels inside the mask.
[0097] Step S33 includes:
[0098] S331: Apply an electric field to the first channel and the second channel to prevent the blue-banded electrogel particles from entering;
[0099] S332: A plurality of the aforementioned blue electrically charged gel particles are emitted onto a photomask using a high-speed gas flow;
[0100] S333: Multiple blue-banded electrogel particles enter multiple third channels inside the mask.
[0101] In this embodiment, an electric field can be set on the photomask, allowing the first, second, and third channels to be controlled individually. In each process, only one type of channel is activated among the first, second, and third channels, forming the corresponding light-emitting portion.
[0102] Figure 4 This is a schematic diagram of a photomask used in this application; see [link / reference]. Figure 4 As shown, this application discloses a photomask 200 used in the above-described method for manufacturing a display panel.
[0103] The mask 200 includes a mask body 210 and multiple channels disposed on the mask body; the multiple channels include multiple first channels 220, multiple second channels 230 and multiple third channels 240; a first control electrode 221 is disposed in the first channel 220, a second control electrode 231 is disposed in the second channel 230, and a third control electrode 241 is disposed in the third channel 240; the multiple first control electrodes 221 are electrically connected to each other, the multiple second control electrodes 231 are electrically connected to each other, and the multiple third control electrodes 241 are electrically connected to each other.
[0104] In the fabrication process of the red light-emitting unit, by not applying an electric field to the first control electrode 221, and applying an electric field of the same charge as the red charged gel particles to the second control electrode 231 and the third control electrode 241, the red charged gel particles can only pass through the first channel. Specifically, a positive electric field is applied when the red charged gel particles are positively charged, and a negative electric field is applied when they are negatively charged. Similarly, by controlling the first control electrode 221, the second control electrode 231, and the third control electrode 241, the red charged gel particles, green charged gel particles, and blue charged gel particles are respectively controlled to pass through the first channel 220, the second channel 230, and the third channel 240.
[0105] This embodiment utilizes an electric field on the photomask to effectively prevent charged gel particles from entering mismatched channels. The electric field, located on the photomask, selectively blocks charged gel particles from entering certain channels before they do, thus preventing them from entering mismatched channels, such as red charged gel particles entering the second or third channel. The electric field prevents red charged gel particles from passing through the second and third channels, thereby avoiding the formation of red emitting particles at non-red sub-pixel locations.
[0106] Since the material that ultimately forms the light-emitting part is only light-emitting particles, it is also necessary to remove the charged gel material. Specifically, step S40 includes the following steps:
[0107] S41: A high-frequency mechanical wave is used to cause a physical change in the multiple red electrically charged gel particles in the first channel, releasing multiple red light-emitting particles. The multiple red light-emitting particles form multiple red light-emitting parts in multiple first opening areas.
[0108] S42: High-frequency mechanical waves are used to cause the multiple green electrified gel particles in the second channel to collapse and release multiple green luminescent particles, which form multiple green luminescent parts in multiple second opening areas;
[0109] S43: High-frequency mechanical waves are used to cause a physical change in the multiple red electrically charged gel particles in the third channel, releasing multiple green luminescent particles. The multiple blue luminescent particles then form multiple blue luminescent portions in multiple third opening regions. These multiple opening regions include multiple first opening regions, multiple second opening regions, and multiple third opening regions.
[0110] In this embodiment, when the red charged gel particles enter the first channel, they undergo a physical change, releasing multiple red luminescent particles that exit the first channel to form a red luminescent portion in the first opening region. Similarly, in the manufacturing processes of the green and blue charged gel particles, high-frequency mechanical wave processing causes the green charged gel particles to collapse, releasing green luminescent particles that exit the second channel to form a green luminescent portion in the second opening region; and causes the blue charged gel particles to collapse, releasing blue luminescent particles that exit the third channel to form a green luminescent portion in the third opening region.
[0111] The high-frequency mechanical waves include ultrasound. Ultrasound causes the red charged aerogel particles to physically collapse, releasing multiple red luminescent particles. This process, known as physical disintegration, is a physical change in which the mechanical force generated by ultrasound disrupts the aerogel's network structure, causing the luminescent particles to be released. Alternatively, the aerogel network structure can be disrupted by heating to melt or cause the polymer chains to move.
[0112] It is understood that the order in which the red, green, and blue light-emitting units are formed can be selected according to the actual situation. This application does not limit the order in which the red, green, and blue light-emitting units are formed, but only describes the order in which they are formed.
[0113] Figure 5 This is a schematic diagram illustrating the steps of a method for manufacturing a display panel according to the second embodiment of this application. See also... Figure 5 As shown, this application also discloses a method for manufacturing a display panel, including the following steps:
[0114] A: Provide a substrate;
[0115] B: Multiple red luminescent material particles are combined with an aerogel polymer precursor to form multiple red electrically charged gel particles; multiple green luminescent material particles are combined with an aerogel polymer precursor to form multiple green electrically charged gel particles; and multiple blue luminescent material particles are combined with an aerogel polymer precursor to form multiple blue electrically charged gel particles.
[0116] C: Apply an electric field to the second and third channels to prevent the red charged gel particles from entering, and emit multiple red charged gel particles into multiple first channels inside the mask. Use high-frequency mechanical waves to cause multiple red charged gel particles in the first channels to undergo physical changes and release multiple red light-emitting particles. Multiple red light-emitting particles form multiple red light-emitting parts in multiple first opening areas.
[0117] D: Apply an electric field to the first channel and the third channel to prevent the green electrified gel particles from entering, and emit multiple green electrified gel particles into multiple second channels inside the mask. Use high-frequency mechanical waves to cause the multiple green electrified gel particles in the second channels to collapse and release multiple green light-emitting particles. The multiple green light-emitting particles form multiple green light-emitting parts in multiple second opening areas.
[0118] E: Apply an electric field to the first channel and the second channel to prevent the blue electrified gel particles from entering, and emit multiple blue electrified gel particles into multiple third channels inside the mask. Use high-frequency mechanical waves to cause multiple red electrified gel particles in the third channels to undergo physical changes and release multiple blue light-emitting particles. Multiple blue light-emitting particles form multiple blue light-emitting parts in multiple third opening areas.
[0119] F: Forms multiple red light-emitting units, multiple green light-emitting units, and multiple blue light-emitting units.
[0120] The mask is provided with multiple first channels, multiple second channels and multiple third channels, and the substrate is provided with multiple first opening regions, multiple second opening regions and multiple third opening regions; the first channels are provided corresponding to the first opening regions, the second channels are provided corresponding to the second opening regions, and the third channels are provided corresponding to the third opening regions.
[0121] In this embodiment, the luminescent material particles and the charged gel polymer precursor are mixed using the aforementioned charged gel material. A catalyst is added, or conditions such as temperature and pH are changed, to form charged gel particles encapsulating the luminescent particles. After drying, a film is deposited, and a high-speed airflow carries the particles to the corresponding spatial positions. Subsequently, the gel is broken down by ultrasonic physical collapse, releasing the luminescent particles, which then form films at the corresponding locations, thereby creating luminescent units of different colors.
[0122] Figure 6 This is a schematic diagram of the display panel of this application; see below. Figure 6 As shown, this application also discloses a display panel, which can be formed using the manufacturing method of the display panel in any of the above embodiments.
[0123] The display panel 100 includes a substrate 110, a pixel definition layer 111 disposed on the substrate 110, and a plurality of light-emitting units 120. The pixel definition layer 111 has a plurality of openings to form a plurality of opening regions. The plurality of light-emitting units 120 are respectively disposed in the plurality of opening regions, and two adjacent light-emitting units 120 are separated by the pixel definition layer 111. The light-emitting unit 120 includes a bottom electrode 121, a light-emitting part 122, and a top electrode 123. The light-emitting part 122 is disposed between the bottom electrode 121 and the top electrode 123. The pixel definition layer 111 includes a bottom 113 and an upper part 112. The upper part 112 is disposed on the side of the bottom 113 away from the substrate. The radial width of the upper part 112 is smaller than the radial width of the bottom 113.
[0124] Because of the aforementioned mask and corresponding display panel manufacturing method, during the emission of light-emitting particles from the mask, the presence of control electrodes within the channel results in a higher concentration of light-emitting particles at the edge of the emission port. This embodiment addresses this by reducing the radial width of the upper portion of the pixel definition layer, thereby increasing the radial width of the pixel definition layer's opening. This facilitates the entry of light-emitting particles from the edge into the opening, increasing the number of particles entering and reducing evaporation loss. Furthermore, by gradually narrowing the opening of the pixel definition layer from top to bottom, light-emitting particles gradually converge from the edge towards the center, guiding them towards the central area.
[0125] In one specific embodiment, the bottom electrode 121 has an arc surface on the side away from the substrate, and the thickness of the bottom electrode gradually decreases from the center line of the bottom electrode 121 to the surrounding area.
[0126] By gradually increasing the thickness of the bottom electrode from both sides towards the center, when forming the light-emitting portion, the thickness of the light-emitting portion at the edge is greater and the thickness of the light-emitting portion at the center is smaller when the side of the light-emitting portion away from the substrate is flat. This method is adapted to fabricate a display panel using this photomask.
[0127] Specifically, the bottom electrode 121 includes a reflective metal layer 1212 and a transparent electrode layer 1211. The transparent electrode layer 1211 is disposed on the side of the reflective metal layer 1212 away from the substrate. The thickness of the transparent electrode layer 1211 gradually decreases from the centerline of the bottom electrode 121 outwards. Specifically, the reflective metal layer has a uniform and flat thickness to better reflect outgoing light.
[0128] Because a control electrode is located at the center of each channel in the photomask, the film thickness at the center of each opening area is less than that at the edges during the evaporation process. Therefore, by processing the surface of the transparent electrode layer in the bottom electrode to create a surface structure with recessed edges and a raised center on the side facing the light-emitting part, the transparent electrode layer has a surface that matches the light-emitting part, making the side of the light-emitting part away from the substrate smoother. This avoids problems such as light scattering loss caused by an uneven film layer on the light-emitting part. It also avoids problems such as unreliable packaging and leakage caused by an uneven film layer on the light-emitting part.
[0129] The plurality of light-emitting units 120 include a plurality of red light-emitting units 120R, a plurality of green light-emitting units 120G, and a plurality of blue light-emitting units 120B; the plurality of opening regions include a plurality of first opening regions 111a, a plurality of second opening regions 111b, and a plurality of third opening regions 111c; the red light-emitting units 120R are located in the first opening region 111a, the green light-emitting units 120G are located in the second opening region 111b, and the blue light-emitting units 120B are located in the third opening region 111c.
[0130] In this embodiment, the light-emitting part generally includes film layers such as a hole injection layer, a hole transport layer, an electron blocking layer, a light-emitting layer, a hole blocking layer, an electron transport layer, and an electron injection layer. The light-emitting parts of different colors, such as red, green, and blue, differ primarily in the material of their light-emitting layers. However, the hole injection layer, hole transport layer, electron blocking layer, electron transport layer, and electron injection layer are made of the same material. This allows for the simultaneous formation of the hole injection layer, hole transport layer, electron blocking layer, electron transport layer, and electron injection layer in different colored light-emitting units by not applying an electric field to the first, second, and third channels respectively.
[0131] It should be noted that the inventive concept of this application can form many embodiments, but due to the limited space of the application documents, they cannot all be listed. Therefore, without conflict, the embodiments described above or the technical features can be arbitrarily combined to form new embodiments. After the embodiments or technical features are combined, the original technical effect will be enhanced.
[0132] The above description, in conjunction with specific optional embodiments, provides a further detailed explanation of this application and should not be construed as limiting the specific implementation of this application to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of this application, and all such modifications or substitutions should be considered within the scope of protection of this application.
Claims
1. A method for manufacturing a display panel, characterized in that, Including the following steps: Provide a substrate; Luminescent material particles are combined with an aerogel polymer precursor to form multiple electrically charged gel particles; wherein, the electrically charged gel particles encapsulate luminescent material particles. Multiple electrically charged gel particles are emitted into multiple channels inside the mask; After undergoing physical changes within the channel, the multiple charged gel particles release multiple luminescent material particles, which then form multiple luminescent portions within multiple opening regions of the substrate. Multiple light-emitting units are formed on the substrate. The number of the plurality of channels is the same as the number of the plurality of opening regions; The step of forming a plurality of electrically charged gel particles from luminescent material particles and an aerogel polymer precursor includes: Multiple red luminescent material particles are combined with an aerogel polymer precursor to form multiple red electrogel particles; multiple green luminescent material particles are combined with an aerogel polymer precursor to form multiple green electrogel particles; multiple blue luminescent material particles are combined with an aerogel polymer precursor to form multiple blue electrogel particles. The plurality of channels include a plurality of first channels, a plurality of second channels, and a plurality of third channels; The step of emitting the plurality of electrically charged gel particles into the plurality of channels inside the mask includes: An electric field is applied to the second and third channels to prevent the red electrically charged gel particles from entering; a plurality of the red electrically charged gel particles are launched onto the mask using a high-speed airflow; the plurality of the red electrically charged gel particles enter the plurality of the first channels inside the mask; An electric field is applied to the first and third channels to prevent the green-banded electrogel particles from entering; a plurality of the green-banded electrogel particles are launched onto the mask using a high-speed airflow; the plurality of the green-banded electrogel particles enter the plurality of the second channels inside the mask; An electric field is applied to the first and second channels to prevent the blue-banded electrogel particles from entering; a plurality of the blue-banded electrogel particles are launched onto the mask using a high-speed airflow; the plurality of the blue-banded electrogel particles enter the plurality of the third channels inside the mask.
2. The method for manufacturing a display panel according to claim 1, characterized in that, The step of releasing multiple luminescent material particles after the plurality of electrically charged gel particles undergo physical changes within the channel, and forming multiple luminescent portions in multiple opening regions of the substrate by the multiple luminescent material particles includes: A high-frequency mechanical wave is used to cause a physical change in the multiple red electrically charged gel particles in the first channel, releasing multiple red luminescent material particles. The multiple red luminescent material particles form multiple red luminescent parts in multiple first opening regions. High-frequency mechanical waves are used to cause a physical change in the multiple green electrogel particles in the second channel, releasing multiple green luminescent material particles. These multiple green luminescent material particles form multiple green luminescent portions in multiple second opening regions. High-frequency mechanical waves are used to cause a physical change in the multiple blue electrogel particles in the third channel, releasing multiple blue luminescent material particles. These multiple blue luminescent material particles form multiple blue luminescent portions in multiple third opening regions. The plurality of opening regions include a plurality of first opening regions, a plurality of second opening regions, and a plurality of third opening regions.
3. A method for manufacturing a display panel, characterized in that, Including the following steps: Provide a substrate; Multiple red luminescent material particles are combined with an aerogel polymer precursor to form multiple red electrically charged gel particles; multiple green luminescent material particles are combined with an aerogel polymer precursor to form multiple green electrically charged gel particles; and multiple blue luminescent material particles are combined with an aerogel polymer precursor to form multiple blue electrically charged gel particles. An electric field is applied to the second and third channels inside the mask to prevent the red charged gel particles from entering. Multiple red charged gel particles are emitted into multiple first channels inside the mask. A high-frequency mechanical wave is used to cause the multiple red charged gel particles in the first channels to undergo physical changes and release multiple red luminescent material particles. Multiple red luminescent material particles form multiple red luminescent parts in multiple first opening areas. An electric field is applied to the first and third channels to prevent the green charged gel particles from entering. Multiple green charged gel particles are emitted into multiple second channels inside the mask. A high-frequency mechanical wave is used to cause a physical change in the multiple green charged gel particles in the second channels, releasing multiple green luminescent material particles. Multiple green luminescent material particles form multiple green luminescent parts in multiple second opening areas. An electric field is applied to the first and second channels to prevent the blue electrified gel particles from entering. Multiple blue electrified gel particles are emitted into multiple third channels inside the mask. A high-frequency mechanical wave is used to cause a physical change in the multiple blue electrified gel particles in the third channels, releasing multiple blue luminescent material particles. The multiple blue luminescent material particles form multiple blue luminescent parts in multiple third opening areas. This forms multiple red light-emitting units, multiple green light-emitting units, and multiple blue light-emitting units; The photomask is provided with multiple first channels, multiple second channels and multiple third channels, and the substrate is provided with multiple first opening regions, multiple second opening regions and multiple third opening regions; The first channel is set in the first opening area, the second channel is set in the second opening area, and the third channel is set in the third opening area.
4. A photomask, characterized in that, The method for manufacturing a display panel as described in any one of claims 1 to 3, wherein the mask comprises a mask body and a plurality of channels disposed on the mask body; The multiple channels include multiple first channels, multiple second channels, and multiple third channels; A first control electrode is provided in the first channel, a second control electrode is provided in the second channel, and a third control electrode is provided in the third channel; The plurality of first control electrodes are electrically connected to each other, the plurality of second control electrodes are electrically connected to each other, and the plurality of third control electrodes are electrically connected to each other.
5. The photomask according to claim 4, characterized in that, The first control electrode is located in the middle of the first channel, the second control electrode is located in the middle of the second channel, and the third control electrode is located in the middle of the third channel; The opening areas of the first channel, the second channel, and the third channel are different.
6. A display panel, characterized in that, The display panel is formed by the manufacturing method of the display panel as described in any one of claims 1-3. The display panel includes a substrate, a pixel definition layer disposed on the substrate, and a plurality of light-emitting units. The pixel definition layer is provided with a plurality of openings to form a plurality of opening regions. The plurality of light-emitting units are respectively disposed in the plurality of opening regions, and two adjacent light-emitting units are separated by the pixel definition layer. The light-emitting unit includes a bottom electrode, a light-emitting part, and a top electrode, wherein the light-emitting part is disposed between the bottom electrode and the top electrode; The pixel definition layer includes a bottom and an upper part, the upper part being disposed on the side of the bottom away from the substrate; the radial width of the upper part is smaller than the radial width of the bottom.
7. The display panel according to claim 6, characterized in that, The bottom electrode has an arc surface on the side away from the substrate, and the thickness of the bottom electrode gradually decreases from the center line of the bottom electrode to the surrounding area. The plurality of light-emitting units include a plurality of red light-emitting units, a plurality of green light-emitting units, and a plurality of blue light-emitting units; The plurality of opening regions include a plurality of first opening regions, a plurality of second opening regions, and a plurality of third opening regions; The red light-emitting unit is located in the first opening area, the green light-emitting unit is located in the second opening area, and the blue light-emitting unit is located in the third opening area.
8. The display panel according to claim 6, characterized in that, The bottom electrode includes a reflective metal layer and a transparent electrode layer. The transparent electrode layer is disposed on the side of the reflective metal layer away from the substrate. The thickness of the transparent electrode layer gradually decreases from the centerline of the bottom electrode outwards.