Display panel, method for manufacturing display panel, and display device

Abstract

This application provides a display panel, a method for fabricating the display panel, and a display device. The display panel includes: a substrate; a plurality of first electrodes disposed on one side of the substrate; each first electrode includes a first conductive layer and a second conductive layer, the second conductive layer being disposed on the side of the first conductive layer away from the substrate; the area of ​​the orthographic projection of the second conductive layer on the substrate is larger than the area of ​​the orthographic projection of the first conductive layer on the substrate, and the orthographic projection of the first conductive layer on the substrate is located within the orthographic projection of the second conductive layer on the substrate; a first pixel defining layer including a plurality of pixel openings, the orthographic projection of the first electrode on the substrate being located within the orthographic projection of the pixel openings on the substrate. The display panel provided by this application, by designing the edge of the second conductive layer in the first electrode to protrude, enables the functional film layer in the subsequently evaporated light-emitting functional layer to naturally break apart, reducing the risk of lateral leakage and the gray spot defect rate.

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 display panel, and a display device. Background Technology

[0002] In traditional display panel manufacturing, a fine metal mask (FMM) is typically used to pattern the light-emitting pixels. FMM technology is mature and has extensive mass production experience. However, FMM technology also suffers from limitations in precision, high development costs, and long development cycles. Fine metal maskless technology eliminates the limitations of traditional OLED processes on display size, resolution, and other screen performance characteristics, offering advantages such as high performance, full-size display, and agile delivery. Patents CN118251982A, CN115666161A, CN116648095A, CN117062489A, CN118678742A, CN118785761A, CN115224220A, CN118678729A, CN118660529A, and CN118660589A describe relevant aspects of fine metal maskless technology and are provided for reference.

[0003] However, current OLED display products are prone to leakage problems. Summary of the Invention

[0004] In view of this, the purpose of this application is to provide a display panel, a method for manufacturing the display panel, and a display device, which reduces the risk of leakage and gray spot defects by optimizing the structure of the first electrode.

[0005] To achieve the above objectives, an embodiment of the first aspect of this application provides a display panel, the display panel comprising:

[0006] substrate;

[0007] A plurality of first electrodes are disposed on one side of the substrate; each first electrode includes a first conductive layer and a second conductive layer, the second conductive layer being disposed on the side of the first conductive layer away from the substrate; the area of ​​the orthographic projection of the second conductive layer on the substrate is larger than the area of ​​the orthographic projection of the first conductive layer on the substrate, and the orthographic projection of the first conductive layer on the substrate is located within the orthographic projection of the second conductive layer on the substrate.

[0008] A first pixel definition layer is disposed on the same side of the substrate as the first electrode; the first pixel definition layer includes a plurality of pixel openings, and the orthographic projection of the first electrode on the substrate is located within the orthographic projection of the pixel openings on the substrate.

[0009] Furthermore, the display panel also includes:

[0010] A light-emitting functional layer is disposed on the side of the first electrode away from the substrate, and the orthogonal projection of the first electrode on the substrate is located within the orthogonal projection of the light-emitting functional layer on the substrate;

[0011] Wherein, at least a portion of the film layer of the light-emitting functional layer is broken at the edge of the second conductive layer;

[0012] Preferably, the light-emitting functional layer includes a hole injection layer, a hole transport layer, and a light-emitting layer stacked along a direction away from the substrate, wherein the hole injection layer and the hole transport layer are disconnected at the edge of the second conductive layer;

[0013] Preferably, the light-emitting functional layer further includes an electron transport layer and an electron injection layer located on the side of the light-emitting layer away from the substrate, wherein the electron transport layer is located between the electron injection layer and the light-emitting layer;

[0014] Preferably, the light-emitting functional layer is at least partially located within the pixel opening.

[0015] Furthermore, the display panel also includes:

[0016] The second electrode is disposed on the side of the light-emitting functional layer away from the substrate, at least part of the second electrode covers the light-emitting functional layer, and extends to the side of the first pixel definition layer away from the substrate;

[0017] Preferably, the first electrode is an anode and the second electrode is a cathode.

[0018] Furthermore, the display panel also includes:

[0019] An isolation structure is disposed on the side of the first pixel definition layer away from the substrate; the isolation structure encloses and forms a plurality of isolation openings, at least a portion of the light-emitting functional layer and the second electrode being located within the corresponding isolation openings;

[0020] Preferably, the pixel opening is connected to the corresponding isolation opening, and the orthographic projection of the pixel opening on the substrate is located within the orthographic projection range of the isolation opening on the substrate.

[0021] Furthermore, the isolation structure includes a support portion and a shielding portion, the shielding portion being located on the side of the support portion away from the substrate, and the orthographic projection of the support portion on the substrate being located within the orthographic projection of the shielding portion on the substrate;

[0022] At least a portion of the second electrode is connected to the support portion.

[0023] Furthermore, the isolation structure also includes an overlap portion located between the first pixel definition layer and the support portion; the overlap portion includes a conductive structure, and the second electrode is electrically connected to the overlap portion; the light-emitting functional layer extends to the side of the overlap portion away from the substrate;

[0024] Preferably, the orthographic projection of the support portion on the substrate is located within the orthographic projection of the overlapping portion on the substrate;

[0025] Preferably, the material of the overlapping portion includes molybdenum;

[0026] Preferably, the material of the support portion includes aluminum;

[0027] Preferably, the material of the shielding portion includes titanium.

[0028] Furthermore, the display panel also includes:

[0029] A first encapsulation layer is disposed on the side of the second electrode away from the substrate; the first encapsulation layer includes a plurality of encapsulation units corresponding to the isolation openings, and the encapsulation units extend from the isolation openings along the sidewalls of the isolation structure to the side of the isolation structure away from the substrate;

[0030] Preferably, the display panel further includes a second encapsulation layer and a third encapsulation layer, the second encapsulation layer covering the first encapsulation layer and the isolation structure, and the second encapsulation layer being located between the first encapsulation layer and the third encapsulation layer;

[0031] Preferably, the first encapsulation layer and the third encapsulation layer are inorganic layers, and the second encapsulation layer is an organic layer and is a planarization layer.

[0032] Furthermore, the first conductive layer includes a first metal oxide layer, and the second conductive layer includes a metal layer and a second metal oxide layer, wherein the metal layer is located between the first metal oxide layer and the second metal oxide layer.

[0033] A second aspect of this application provides a display panel, the display panel comprising:

[0034] substrate;

[0035] Multiple first electrodes are disposed on one side of the substrate; each first electrode includes a first conductive layer and a second conductive layer, the second conductive layer is disposed on the side of the first conductive layer away from the substrate, and the edge of the second conductive layer protrudes outward from the edge of the first conductive layer to form an undercut structure;

[0036] A light-emitting functional layer is disposed on the side of the first electrode away from the substrate, and at least a portion of the film layer of the light-emitting functional layer is broken at the undercut structure.

[0037] Furthermore, the light-emitting functional layer includes a hole injection layer, a hole transport layer, and a light-emitting layer stacked along a direction away from the substrate, wherein the hole injection layer and the hole transport layer are disconnected at the undercut structure;

[0038] Preferably, the light-emitting functional layer further includes an electron transport layer and an electron injection layer located on the side of the light-emitting layer away from the substrate, wherein the electron transport layer is located between the electron injection layer and the light-emitting layer.

[0039] Furthermore, the display panel also includes:

[0040] The second electrode is disposed on the side of the light-emitting functional layer away from the substrate;

[0041] Preferably, the light-emitting functional layer is broken at the edge of the second conductive layer to form a first part and a second part; the second electrode covers the first part and the second part and fills the gap between the first part and the second part;

[0042] Preferably, the first electrode is an anode and the second electrode is a cathode.

[0043] Furthermore, the display panel also includes:

[0044] A first pixel definition layer is disposed on the same side of the substrate as the first electrode; the first pixel definition layer includes a plurality of pixel openings, and the first electrode is at least partially located within the corresponding pixel opening;

[0045] An isolation structure is disposed on the side of the first pixel definition layer away from the substrate; the isolation structure encloses and forms a plurality of isolation openings, and the light-emitting functional layer is located within the corresponding isolation opening;

[0046] Preferably, the pixel opening is connected to the corresponding isolation opening.

[0047] The third aspect of this application provides a method for manufacturing a display panel, the method comprising:

[0048] A first conductive layer and a second conductive layer are sequentially disposed on one side of a substrate. The first conductive layer and the second conductive layer are patterned to form a plurality of first electrodes. The edge of the second conductive layer protrudes outward from the edge of the first conductive layer.

[0049] A first pixel definition layer is disposed on the same side of the substrate as the first electrode;

[0050] An isolation layer is provided on the side of the first pixel definition layer away from the substrate. The isolation layer is patterned to form an isolation structure and a plurality of isolation openings enclosed by the isolation structure.

[0051] The first pixel definition layer is graphically processed to form multiple pixel openings, which are connected to the corresponding isolation openings. The first electrode is located within the corresponding pixel opening.

[0052] Furthermore, the method also includes:

[0053] A light-emitting functional layer, a second electrode, and a packaging unit are sequentially stacked on the side of the first electrode away from the substrate. The packaging unit covers the second electrode and part of the isolation structure. The light-emitting functional layer includes a hole injection layer, a hole transport layer, and a light-emitting layer stacked along a direction away from the substrate. The hole injection layer and the hole transport layer are disconnected at the edge of the second conductive layer.

[0054] Preferably, the light-emitting functional layer further includes an electron transport layer and an electron injection layer located on the side of the light-emitting layer away from the substrate, wherein the electron transport layer is located between the electron injection layer and the light-emitting layer.

[0055] An embodiment of the fourth aspect of this application provides a display device including a display panel of any of the above embodiments.

[0056] The display panel provided in this application, by protruding the edge of the second conductive layer in the first electrode, enables the functional film layer in the subsequently evaporated light-emitting functional layer to be broken at the edge of the second conductive layer, thereby reducing the risk of lateral leakage and the gray spot defect rate. Attached Figure Description

[0057] To more clearly illustrate the technical solutions in this application or related technologies, the drawings used in the description of the embodiments or related technologies will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0058] Figure 1 This is a schematic diagram of the hierarchical structure of a display panel in related technologies;

[0059] Figure 2 A schematic diagram of the hierarchical structure of a display panel provided in an embodiment of this application;

[0060] Figure 3 A schematic diagram of a partial hierarchical structure of a display panel provided in an embodiment of this application;

[0061] Figure 4 This is a schematic diagram of the hierarchical structure of the light-emitting functional layer provided in an embodiment of this application;

[0062] Figure 5 This is a schematic diagram of the hierarchical structure of a display panel provided in another embodiment of this application;

[0063] Figure 6 This is a schematic flowchart of a method for manufacturing a display panel according to an embodiment of this application;

[0064] Figure 7 This is a schematic diagram of the layer structure of a display panel provided in the embodiment of this application during the manufacturing process;

[0065] Figure 8 This is a schematic diagram of the layer structure of a display panel provided in the embodiment of this application during the manufacturing process.

[0066] Marker explanation:

[0067] 100. Display panel; 1. Substrate; 2. Light-emitting unit; 21. First electrode; 211. First conductive layer; 212. Second conductive layer; 210. Undercut structure; 22. Light-emitting functional layer; 2201. First part; 2202. Second part; 221. Hole injection layer; 222. Hole transport layer; 223. Light-emitting layer; 224. Electron transport layer; 225. Electron injection layer; 23. Second electrode; 3. First pixel definition layer; 301. First pixel material layer; 30. Pixel opening; 4. Isolation structure; 401. Isolation layer; 40. Isolation opening; 41. Support part; 42. Shielding part; 43. Overlapping part; 51. First encapsulation layer; 510. Encapsulation unit; 52. Second encapsulation layer; 53. Third encapsulation layer. Detailed Implementation

[0068] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with specific embodiments and the accompanying drawings.

[0069] It should be noted that, unless otherwise defined, the technical or scientific terms used in the embodiments of this application should have the ordinary meaning understood by one of ordinary skill in the art to which this application pertains. The terms "first," "second," and similar terms used in the embodiments of this application do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed after the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are only used to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0070] In the accompanying drawings, the dimensions of layers and regions may be exaggerated for clarity. It is understood that when a structure is referred to as being "on" or "below" another structure, the structure may be directly on or below the other structure, or there may be intermediate structures. The same reference numerals always indicate the same structure. Structures referred to herein include any of the following: membrane, element, device, component, assembly.

[0071] When a structure is referred to as being “connected” to another structure, it can be directly connected to the other structure or indirectly connected to the other structure by means of one or more intermediate structures placed between them.

[0072] like Figure 1 As shown, in the related technology, the functional film layers of adjacent light-emitting units 2 can be separated by the isolation structure 4. In this way, in the evaporation process of the functional film layers, it is only necessary to perform evaporation on the entire display panel, without the need to prepare the functional film layer of each light-emitting unit separately with the help of a metal mask. This technology is a maskless self-alignment pixelation technology, which does not need to consider the alignment accuracy problem during evaporation, thereby allowing the gap between the light-emitting units to be designed to be smaller.

[0073] Specifically, the light-emitting unit 2 includes a first electrode 21, a light-emitting functional layer, and a second electrode 23. The light-emitting functional layer includes a hole injection layer 221, a hole transport layer 222, and a light-emitting layer 223. The inventors of this application have discovered that the hole injection layer 221 and the hole transport layer 222 in the light-emitting functional layer overlap with the conductive portion of the isolation structure 4 (such as the underlying molybdenum metal). This causes the current in the first electrode 21 to flow laterally through the hole injection layer 221 or the hole transport layer 222, and to conduct through the overlapping isolation structure 4, resulting in a current response under low voltage and increasing the risk of leakage current. Furthermore, the overlap between the hole injection layer 221 or the hole transport layer 222 and the isolation structure 4 affects the overlap between the second electrode 23 and the isolation structure 4, leading to gray spot (non-uniform display) defects.

[0074] Based on this, this application provides a display panel solution to solve the above problems.

[0075] like Figure 2 , Figure 3 As shown, an embodiment of the first aspect of this application provides a display panel 100, which includes a substrate 1, a plurality of first electrodes 21, and a first pixel definition layer 3. The plurality of first electrodes 21 are disposed on one side of the substrate 1. Each first electrode 21 includes a first conductive layer 211 and a second conductive layer 212, the second conductive layer 212 being disposed on the side of the first conductive layer 211 away from the substrate 1; the area of ​​the orthographic projection of the second conductive layer 212 onto the substrate 1 is larger than the area of ​​the orthographic projection of the first conductive layer 211 onto the substrate 1, and the orthographic projection of the first conductive layer 211 onto the substrate 1 lies within the orthographic projection of the second conductive layer 212 onto the substrate 1. The first pixel definition layer 3 is disposed on the same side of the substrate 1 as the first electrodes 21. The first pixel definition layer 3 includes a plurality of pixel openings 30, and the orthographic projection of the first electrodes 21 onto the substrate 1 lies within the orthographic projection of the pixel openings 30 onto the substrate 1.

[0076] Specifically, a first electrode 21 is disposed on the substrate 1 of the display panel 100. The bottom layer of the first electrode 21 is a first conductive layer 211, and the top layer of the first electrode 21 is a second conductive layer 212. Through photolithography and etching processes, the lateral dimension of the second conductive layer 212 is made larger than that of the first conductive layer 211, and the edge of the first conductive layer 211 is recessed relative to the edge of the second conductive layer 212, thus forming an undercut structure 210. The undercut structure 210 can block the lateral extension path of some functional film layers in the lateral light-emitting functional layer, reducing leakage current. The pixel opening 30 of the first pixel defining layer 3 corresponds to the position of the first electrode 21. The first electrode 21 does not exceed the edge of the pixel opening 30, precisely defining the light-emitting area and improving display uniformity. Among them, the undercut structure 210, through the design of the second conductive layer 212 extending outward, physically blocks the lateral extension path of the light-emitting functional layer, preventing the current of the first electrode 21 from conducting with the isolation structure 4, and reducing the risk of lateral leakage current. Meanwhile, the pixel opening 30 is used to define the light-emitting area, reduce gray spot defects caused by poor overlap, and improve display uniformity.

[0077] In the aforementioned display panel 100, the edge protrusion structure of the second conductive layer 212 enables the subsequent vapor-deposited light-emitting functional layer to be naturally disconnected, thereby physically isolating the functional film layer. For example, it disconnects the lateral current path between the hole injection layer 221 and the hole transport layer 222 in the light-emitting functional layer and the conductive part of the isolation structure 4. Even if the hole injection layer 221 or the hole transport layer 222 climbs up to the side wall of the isolation structure 4, there will be no leakage of the first electrode 21 through the hole injection layer 221 or the hole transport layer 222, thus reducing the risk of lateral leakage and the gray spot defect rate.

[0078] Furthermore, the display panel 100 also includes a light-emitting functional layer 22, which is disposed on the side of the first electrode 21 away from the substrate 1, and the orthographic projection of the first electrode 21 on the substrate 1 lies within the orthographic projection of the light-emitting functional layer 22 on the substrate 1. At least a portion of the film layer of the light-emitting functional layer 22 is broken at the edge of the second conductive layer 212.

[0079] Optionally, such as Figure 4 As shown, the light-emitting functional layer 22 includes a hole injection layer 221, a hole transport layer 222, and a light-emitting layer 223 stacked along a direction away from the substrate 1. The hole injection layer 221 and the hole transport layer 222 are disconnected at the edge of the second conductive layer 212. Optionally, the light-emitting functional layer 22 further includes an electron transport layer 224 and an electron injection layer 225 located on the side of the light-emitting layer 223 away from the substrate 1. The electron transport layer 224 is located between the electron injection layer 225 and the light-emitting layer 223.

[0080] In other embodiments, all the film layers of the light-emitting functional layer 22 are broken at the edge of the second conductive layer 212.

[0081] Optionally, the light-emitting functional layer 22 is at least partially located within the pixel opening 30.

[0082] Specifically, the light-emitting functional layer 22 may include a hole injection layer 221 (HIL), a hole transport layer 222 (HTL), an emission layer 223 (EML), an electron transport layer 224 (ETL), and an electron injection layer 225 (EIL) stacked sequentially. The hole injection layer 221 and the hole transport layer 222 are disconnected at the edges of the second conductive layer 212, thereby breaking the leakage path between the first electrode 21 and the isolation structure 4 and eliminating abnormal current response under low voltage. The light-emitting functional layer 22 is precisely aligned with the first electrode 21 within the pixel opening 30, ensuring uniform electric field distribution, improving luminous efficiency, and reducing crosstalk between sub-pixels. Furthermore, the disconnection point is located at the edge of the second conductive layer 212, which avoids affecting the luminous efficiency of the emission layer 223 and improves brightness uniformity.

[0083] Furthermore, the display panel 100 also includes a second electrode 23, which is disposed on the side of the light-emitting functional layer 22 away from the substrate 1. At least a portion of the second electrode 23 covers the light-emitting functional layer 22, and the second electrode 23 extends to the side of the first pixel definition layer 3 away from the substrate 1.

[0084] Optionally, the first electrode 21 is the anode and the second electrode 23 is the cathode.

[0085] Specifically, the second electrode 23 covers the light-emitting functional layer 22, and the second electrode 23, acting as a cathode, forms an electric field with the first electrode 21, which acts as an anode, to drive light emission. The vertical electric field design between the cathode and anode optimizes carrier injection efficiency and reduces driving voltage.

[0086] In some embodiments, the display panel 100 further includes an isolation structure 4 disposed on the side of the first pixel definition layer 3 away from the substrate 1. The isolation structure 4 encloses and forms a plurality of isolation openings 40, with at least a portion of the light-emitting functional layer 22 and the second electrode 23 located within the corresponding isolation opening 40.

[0087] Optionally, the pixel opening 30 is connected to the corresponding isolation opening 40, and the orthographic projection of the pixel opening 30 on the substrate 1 is within the orthographic projection range of the isolation opening 40 on the substrate 1, which simplifies the opening alignment process. Specifically, a portion of the light-emitting functional layer 22 and the second electrode 23 are located within the isolation opening 40, and another portion is located within the pixel opening 30. The position of the light-emitting unit can be precisely defined by the pixel opening 30 and the isolation opening 40. Further, the isolation structure 4 includes a support portion 41 and a shielding portion 42. The shielding portion 42 is located on the side of the support portion 41 away from the substrate 1, and the orthographic projection of the support portion 41 on the substrate 1 is within the orthographic projection of the shielding portion 42 on the substrate 1. At least a portion of the second electrode 23 is connected to the support portion 41. In some embodiments, the isolation structure 4 further includes an overlap portion 43, which is located between the first pixel definition layer 3 and the support portion 41; the overlap portion 43 includes a conductive structure, and the second electrode 23 is electrically connected to the overlap portion 43. The light-emitting functional layer 22 extends to the side of the overlap portion 43 away from the substrate 1.

[0088] Optionally, the orthographic projection of the support portion 41 on the substrate 1 is located within the orthographic projection of the overlapping portion 43 on the substrate 1.

[0089] Optionally, the material of the overlapping part 43 includes molybdenum, the material of the support part 41 includes aluminum, and the material of the shielding part 42 includes titanium.

[0090] Specifically, the portion of the isolation structure 4 at least away from the substrate 1 is designed to be wider at the top and narrower at the bottom, thereby allowing the isolation structure 4 to block the light-emitting functional layer 22 of adjacent light-emitting units, thus reducing current crosstalk between adjacent light-emitting units. The overlapping portion 43 forms a stable electrical connection with the second electrode 23, reducing contact resistance and improving device reliability. The high reflectivity of the titanium shielding portion 42 enhances light extraction efficiency, while the aluminum support portion 41 provides mechanical stability. The isolation structure 4 adopts an aluminum-titanium-molybdenum composite structure that balances conductivity, reflectivity, and mechanical strength. The high reflectivity of the titanium layer improves display brightness, and the molybdenum overlapping portion enhances the reliability of the cathode connection, preventing display failure due to poor contact.

[0091] like Figure 5 As shown, in some embodiments, the display panel 100 further includes a first encapsulation layer 51 disposed on the side of the second electrode 23 away from the substrate 1; the first encapsulation layer 51 includes a plurality of encapsulation units 510 corresponding to the isolation opening 40, and the encapsulation units 510 extend from the isolation opening 40 along the sidewall of the isolation structure 4 to the side of the isolation structure 4 away from the substrate 1.

[0092] Optionally, the display panel 100 further includes a second encapsulation layer 52 and a third encapsulation layer 53. The second encapsulation layer 52 covers the first encapsulation layer 51 and the isolation structure 4, and is located between the first encapsulation layer 51 and the third encapsulation layer 53. Optionally, the first encapsulation layer 51 and the third encapsulation layer 53 are inorganic layers, and the second encapsulation layer 52 is an organic layer and is a planarization layer.

[0093] Specifically, the encapsulation structure located above the light-emitting unit 2 in the isolation opening 40 includes alternating stacked inorganic and organic layers. The encapsulation unit 510 in the first encapsulation layer 51 can fill the corresponding isolation opening 40 and cover the second electrode 23. The second encapsulation layer is an organic planarization layer, and the third encapsulation layer is an inorganic protective layer. This inorganic-organic-inorganic stacked encapsulation effectively blocks water and oxygen penetration, extending device lifespan. The organic planarization layer eliminates surface unevenness, reduces optical distortion, and ensures consistent display colors.

[0094] In one embodiment, the first conductive layer 211 includes a first metal oxide layer, and the second conductive layer 212 includes a metal layer and a second metal oxide layer, with the metal layer located between the first and second metal oxide layers. Specifically, the first conductive layer is made of indium tin oxide (ITO), and the second conductive layer is a stacked structure of silver (Ag) and indium tin oxide (ITO), with an undercut edge formed by sputtering and etching processes. The high conductivity of the silver layer reduces the anode resistance and decreases driving power consumption. The ITO / Ag / ITO stacked structure improves the anode reflectivity and enhances the light extraction efficiency of the light-emitting layer, while the undercut design blocks lateral leakage current in the HIL / HTL layers.

[0095] In one embodiment, the light-emitting unit 2 includes a first-color light-emitting unit, a second-color light-emitting unit, and a third-color light-emitting unit for emitting different colors of light. For example, the first-color light-emitting unit, the second-color light-emitting unit, and the third-color light-emitting unit emit red light, green light, and blue light, respectively. The multiple color light-emitting units, separated by the isolation structure 4, achieve independent color control, avoid color crosstalk, and improve the color gamut coverage and color reproduction of the display panel.

[0096] In the process of forming the light-emitting unit 2, firstly, a full-area vapor deposition is performed to complete the deposition of the first color light-emitting layer and functional layer. Then, a full-area thin-film encapsulation is performed. Next, through patterning processing, the parts on the substrate that do not need to be retained are selectively removed to form the first color light-emitting unit. Then, the above process is repeated twice more to form the second color light-emitting unit and the third color light-emitting unit, completing the full-color patterning of the three primary colors of red, green and blue (RGB).

[0097] An embodiment of the second aspect of this application provides a display panel 100, which includes a substrate 1, a plurality of first electrodes 21, and a light-emitting functional layer 22. The plurality of first electrodes 21 are disposed on one side of the substrate 1. Each first electrode 21 includes a first conductive layer 211 and a second conductive layer 212. The second conductive layer 212 is disposed on the side of the first conductive layer 211 away from the substrate 1, and the edge of the second conductive layer 212 protrudes outward from the edge of the first conductive layer 211, forming an undercut structure 210. The light-emitting functional layer 22 is disposed on the side of the first electrode 21 away from the substrate 1, and part or all of the film layers of the light-emitting functional layer 22 are broken at the undercut structure 210.

[0098] Specifically, the undercut structure 210 can be formed by an etching process. The edge of the second conductive layer 212 protrudes outward from the first conductive layer 211, and the film layers within the light-emitting functional layer 22, such as the hole injection layer and the hole transport layer, naturally fracture at the undercut structure 210. The physical isolation effect of the undercut structure 210 breaks the lateral conductive paths of the film layers in the light-emitting functional layer 22, solving the leakage problem. Furthermore, the fracture interface at the undercut structure 210 is smooth, avoiding gray spot defects caused by film residue.

[0099] Furthermore, the light-emitting functional layer 22 includes a hole injection layer 221, a hole transport layer 222, and a light-emitting layer 223 stacked along a direction away from the substrate 1, wherein the hole injection layer 221 and the hole transport layer 222 are disconnected at the undercut structure 210. Optionally, the light-emitting functional layer 22 further includes an electron transport layer 224 and an electron injection layer 225 located on the side of the light-emitting layer 223 away from the substrate 1, wherein the electron transport layer 224 is located between the electron injection layer 225 and the light-emitting layer 223.

[0100] Furthermore, the display panel 100 also includes a second electrode 23, which is disposed on the side of the light-emitting functional layer 22 away from the substrate 1. Optionally, the first electrode 21 is an anode and the second electrode 23 is a cathode.

[0101] Optionally, the light-emitting functional layer 22 is broken at the edge of the second conductive layer 212 to form a first portion 2201 and a second portion 2202; the second electrode 23 covers the first portion 2201 and the second portion 2202 and fills the gap between the first portion 2201 and the second portion 2202.

[0102] The undercut structure 210 prevents short circuits between the first electrode 21 and the second electrode 23, ensuring device stability. The second electrode 23 covers the broken portion of the light-emitting functional layer 22, forming a continuous conductive path and ensuring a uniform electric field distribution.

[0103] Furthermore, the display panel 100 also includes a first pixel definition layer 3 and an isolation structure 4. The first pixel definition layer 3 and the first electrode 21 are disposed on the same side of the substrate 1. The first pixel definition layer 3 includes a plurality of pixel openings 30, and the first electrode 21 is at least partially located within a corresponding pixel opening 30. The isolation structure 4 is disposed on the side of the first pixel definition layer 3 away from the substrate 1; the isolation structure 4 encloses to form a plurality of isolation openings 40, and the light-emitting functional layer 22 is located within a corresponding isolation opening 40. The pixel openings 30 are connected to the corresponding isolation openings 40.

[0104] Specifically, an isolation structure 4 is provided on the first pixel definition layer 3. The isolation structure 4 surrounds the pixel opening 30, defining the isolation opening 40, through which light emitted by the light-emitting unit 2 can exit. Optionally, the isolation structure 4 can be a mesh structure. When performing a vapor deposition process on the display panel 100, the isolation structure 4 can be used to perform whole-layer vapor deposition on the display panel 100 without the need for a mask with vapor deposition openings. The isolation structure 4 can directly isolate the vapor-deposited film layer, thereby avoiding crosstalk caused by lateral leakage between adjacent pixel openings 30, and also eliminating the need for higher resolution and precision requirements on the mask.

[0105] It should be noted that the isolation structure 4 can isolate the light-emitting functional layer to form multiple spaced light-emitting units 2. Although the isolation structure 4 forms an isolation between the second electrodes 23, the conductive structure of the isolation structure 4 can also conduct electricity to the second electrodes 23.

[0106] like Figure 6 , Figure 7 , Figure 8 As shown, an embodiment of the third aspect of this application provides a method for manufacturing a display panel, the method comprising the following steps:

[0107] Step S1: A first conductive layer 211 and a second conductive layer 212 are sequentially disposed on one side of the substrate 1. The first conductive layer 211 and the second conductive layer 212 are patterned to form a plurality of first electrodes 21. The edge of the second conductive layer 212 protrudes outward from the edge of the first conductive layer 211.

[0108] Step S2: A first pixel definition layer 3 is formed on the same side of the substrate 1 as the first electrode 21;

[0109] Step S3: An isolation layer 401 is provided on the side of the first pixel definition layer 3 away from the substrate 1. The isolation layer 401 is patterned to form an isolation structure 4 and a plurality of isolation openings 40 enclosed by the isolation structure 4.

[0110] Step S4: The first pixel definition layer 3 is graphically processed to form multiple pixel openings 30. The pixel openings 30 are connected to the corresponding isolation openings 40, and the first electrode 21 is located in the corresponding pixel opening 30.

[0111] In the above-mentioned method for manufacturing the display panel, the edge protrusion structure of the second conductive layer 212 enables the functional film layer in the subsequently evaporated light-emitting functional layer to be naturally disconnected, forming a physical barrier, thereby reducing the risk of lateral leakage and the gray spot defect rate.

[0112] Furthermore, the method for manufacturing the display panel also includes the following steps:

[0113] Step S5: A light-emitting functional layer 22, a second electrode 23, and an encapsulation unit 510 are formed sequentially on the side of the first electrode 21 away from the substrate 1. The encapsulation unit 510 covers the second electrode 23 and part of the isolation structure 4. The light-emitting functional layer 22 includes a hole injection layer 221, a hole transport layer 222, and a light-emitting layer 223 stacked along the direction away from the substrate 1. The hole injection layer 221 and the hole transport layer 222 are disconnected at the edge of the second conductive layer 212.

[0114] Optionally, the light-emitting functional layer 22 includes an electron transport layer 224 and an electron injection layer 225 located on the side of the light-emitting layer 223 away from the substrate 1, with the electron transport layer 224 located between the electron injection layer 225 and the light-emitting layer 223.

[0115] Specifically, the light-emitting unit 2 includes a first-color light-emitting unit, a second-color light-emitting unit, and a third-color light-emitting unit for emitting light of different colors. The isolation opening 40 includes a first-type isolation opening, a second-type isolation opening, and a third-type isolation opening, respectively corresponding to the first-color light-emitting unit, the second-color light-emitting unit, and the third-color light-emitting unit. Step S5 may include:

[0116] Step S51: A first color light-emitting layer, a first color electrode, and a first color encapsulation layer are sequentially formed inside the isolation opening and on the isolation structure.

[0117] Step S52: Pattern the first color encapsulation layer, the first color light-emitting layer, and the first color electrode; remove the first color encapsulation layer, the first color electrode, and the first color light-emitting layer from the isolation structure, the second type of isolation opening, and the third type of isolation opening to form a first color light-emitting unit and a corresponding encapsulation unit.

[0118] Specifically, the first color encapsulation layer on the isolation structure, inside the second type of isolation opening and the third type of isolation opening, can be removed firstly using an etching process, and then the first color electrode and the first color emitting layer on the isolation structure, inside the second type of isolation opening and the third type of isolation opening, can be removed using another etching process. The etching process can be either dry etching or wet etching.

[0119] The first electrode, the first color emitting layer, and the first color electrode together constitute the first color emitting unit.

[0120] Step S53: A second color light-emitting layer, a second color electrode, and a second color encapsulation layer are sequentially formed inside the isolation opening and on the isolation structure.

[0121] Step S54: Pattern the second color encapsulation layer, the second color light-emitting layer, and the second color electrode; remove the second color encapsulation layer, the second color electrode, and the second color light-emitting layer from the isolation structure and from the first type of isolation opening and the third type of isolation opening to form a second color light-emitting unit and a corresponding encapsulation unit.

[0122] Specifically, the second color encapsulation layer on the isolation structure and inside the first type of isolation opening and the third type of isolation opening can be removed first by an etching process, and then the second color electrode and the second color light-emitting layer on the isolation structure and inside the first type of isolation opening and the third type of isolation opening can be removed by another etching process.

[0123] The first electrode, the second color light-emitting layer, and the second color electrode together form the second color light-emitting unit.

[0124] Step S55: A third color light-emitting layer, a third color electrode, and a third color encapsulation layer are sequentially formed inside the isolation opening and on the isolation structure.

[0125] Step S56: Pattern the third color encapsulation layer, the third color light-emitting layer, and the third color electrode; remove the third color encapsulation layer, the third color light-emitting layer, and the third color electrode from the isolation structure and from the first type of isolation opening and the second type of isolation opening to form a third color light-emitting unit and a corresponding encapsulation unit.

[0126] Specifically, the third color encapsulation layer on the isolation structure and inside the first and second type isolation openings can be removed first by an etching process, and then the third color electrode and the third color light-emitting layer on the isolation structure and inside the first and second type isolation openings can be removed by another etching process.

[0127] The first electrode, the third color light-emitting layer, and the third color electrode together form the third color light-emitting unit.

[0128] An embodiment of the fourth aspect of this application also provides a display device, which includes the display panel of any of the above embodiments.

[0129] The display device in this application embodiment can be any product or component with display function, such as a television, digital camera, mobile phone, watch, tablet computer, laptop computer, or navigator.

[0130] Although this application has been described in conjunction with specific embodiments thereof, many substitutions, modifications and variations of these embodiments will be apparent to those skilled in the art from the foregoing description.

[0131] It should be noted that the above description describes some embodiments of this application. Other embodiments are within the scope of the appended claims. In some cases, the actions or steps recorded in the claims can be performed in a different order than that shown in the above embodiments and still achieve the desired result. Furthermore, the processes depicted in the drawings do not necessarily require a specific or sequential order to achieve the desired result. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0132] The embodiments of this application are intended to cover all such substitutions, modifications, and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the embodiments of this application should be included within the protection scope of this application.

Claims

1. A display panel, characterized in that, include: substrate; A plurality of first electrodes are disposed on one side of the substrate; each first electrode includes a first conductive layer and a second conductive layer, the second conductive layer being disposed on the side of the first conductive layer away from the substrate; the area of ​​the orthographic projection of the second conductive layer on the substrate is larger than the area of ​​the orthographic projection of the first conductive layer on the substrate, and the orthographic projection of the first conductive layer on the substrate is located within the orthographic projection of the second conductive layer on the substrate. The first pixel definition layer is disposed on the same side of the substrate as the first electrode; The first pixel definition layer includes a plurality of pixel openings, and the orthographic projection of the first electrode on the substrate is located within the orthographic projection of the pixel openings on the substrate.

2. The display panel according to claim 1, characterized in that, The display panel also includes: A light-emitting functional layer is disposed on the side of the first electrode away from the substrate, and the orthogonal projection of the first electrode on the substrate is located within the orthogonal projection of the light-emitting functional layer on the substrate; Wherein, at least a portion of the film layer of the light-emitting functional layer is broken at the edge of the second conductive layer; Preferably, the light-emitting functional layer includes a hole injection layer, a hole transport layer, and a light-emitting layer stacked along a direction away from the substrate, wherein the hole injection layer and the hole transport layer are disconnected at the edge of the second conductive layer; Preferably, the light-emitting functional layer further includes an electron transport layer and an electron injection layer located on the side of the light-emitting layer away from the substrate, wherein the electron transport layer is located between the electron injection layer and the light-emitting layer; Preferably, the light-emitting functional layer is at least partially located within the pixel opening.

3. The display panel according to claim 2, characterized in that, The display panel also includes: The second electrode is disposed on the side of the light-emitting functional layer away from the substrate, at least part of the second electrode covers the light-emitting functional layer, and extends to the side of the first pixel definition layer away from the substrate; Preferably, the first electrode is an anode and the second electrode is a cathode.

4. The display panel according to claim 3, characterized in that, The display panel also includes: An isolation structure is disposed on the side of the first pixel definition layer away from the substrate; the isolation structure encloses and forms a plurality of isolation openings, at least a portion of the light-emitting functional layer and the second electrode being located within the corresponding isolation openings; Preferably, the pixel opening is connected to the corresponding isolation opening, and the orthographic projection of the pixel opening on the substrate is located within the orthographic projection range of the isolation opening on the substrate.

5. The display panel according to claim 4, characterized in that, The isolation structure includes a support portion and a shielding portion. The shielding portion is located on the side of the support portion away from the substrate, and the orthographic projection of the support portion on the substrate is located within the orthographic projection of the shielding portion on the substrate. At least a portion of the second electrode is connected to the support portion.

6. The display panel according to claim 5, characterized in that, The isolation structure further includes an overlap portion located between the first pixel definition layer and the support portion; the overlap portion includes a conductive structure, and the second electrode is electrically connected to the overlap portion; The light-emitting functional layer extends to the side of the overlapping portion away from the substrate; Preferably, the orthographic projection of the support portion on the substrate is located within the orthographic projection of the overlapping portion on the substrate; Preferably, the material of the overlapping portion includes molybdenum; Preferably, the material of the support portion includes aluminum; Preferably, the material of the shielding portion includes titanium.

7. The display panel according to claim 4, characterized in that, The display panel also includes: A first encapsulation layer is disposed on the side of the second electrode away from the substrate; the first encapsulation layer includes a plurality of encapsulation units corresponding to the isolation openings, and the encapsulation units extend from the isolation openings along the sidewalls of the isolation structure to the side of the isolation structure away from the substrate; Preferably, the display panel further includes a second encapsulation layer and a third encapsulation layer, the second encapsulation layer covering the first encapsulation layer and the isolation structure, and the second encapsulation layer being located between the first encapsulation layer and the third encapsulation layer; Preferably, the first encapsulation layer and the third encapsulation layer are inorganic layers, and the second encapsulation layer is an organic layer and is a planarization layer.

8. The display panel according to claim 1, characterized in that, The first conductive layer includes a first metal oxide layer, and the second conductive layer includes a metal layer and a second metal oxide layer, wherein the metal layer is located between the first metal oxide layer and the second metal oxide layer.

9. A display panel, characterized in that, include: substrate; Multiple first electrodes are disposed on one side of the substrate; each first electrode includes a first conductive layer and a second conductive layer, the second conductive layer is disposed on the side of the first conductive layer away from the substrate, and the edge of the second conductive layer protrudes outward from the edge of the first conductive layer to form an undercut structure; A light-emitting functional layer is disposed on the side of the first electrode away from the substrate, and at least a portion of the film layer of the light-emitting functional layer is broken at the undercut structure.

10. The display panel according to claim 9, characterized in that, The light-emitting functional layer includes a hole injection layer, a hole transport layer and a light-emitting layer stacked along a direction away from the substrate, wherein the hole injection layer and the hole transport layer are disconnected at the undercut structure; Preferably, the light-emitting functional layer further includes an electron transport layer and an electron injection layer located on the side of the light-emitting layer away from the substrate, wherein the electron transport layer is located between the electron injection layer and the light-emitting layer.

11. The display panel according to claim 9, characterized in that, The display panel also includes: The second electrode is disposed on the side of the light-emitting functional layer away from the substrate; Preferably, the light-emitting functional layer is broken at the edge of the second conductive layer to form a first part and a second part; the second electrode covers the first part and the second part and fills the gap between the first part and the second part; Preferably, the first electrode is an anode and the second electrode is a cathode.

12. The display panel according to claim 9, characterized in that, The display panel also includes: A first pixel definition layer is disposed on the same side of the substrate as the first electrode; the first pixel definition layer includes a plurality of pixel openings, and the first electrode is at least partially located within the corresponding pixel opening; An isolation structure is disposed on the side of the first pixel definition layer away from the substrate; the isolation structure encloses and forms a plurality of isolation openings, and the light-emitting functional layer is located within the corresponding isolation opening; Preferably, the pixel opening is connected to the corresponding isolation opening.

13. A method for manufacturing a display panel, characterized in that, The method includes: A first conductive layer and a second conductive layer are sequentially disposed on one side of a substrate. The first conductive layer and the second conductive layer are patterned to form a plurality of first electrodes. The edge of the second conductive layer protrudes outward from the edge of the first conductive layer. A first pixel definition layer is disposed on the same side of the substrate as the first electrode; An isolation layer is provided on the side of the first pixel definition layer away from the substrate. The isolation layer is patterned to form an isolation structure and a plurality of isolation openings enclosed by the isolation structure. The first pixel definition layer is graphically processed to form multiple pixel openings, which are connected to the corresponding isolation openings. The first electrode is located within the corresponding pixel opening.

14. The method for manufacturing a display panel according to claim 13, characterized in that, The method further includes: A light-emitting functional layer, a second electrode, and a packaging unit are sequentially stacked on the side of the first electrode away from the substrate. The packaging unit covers the second electrode and part of the isolation structure. The light-emitting functional layer includes a hole injection layer, a hole transport layer, and a light-emitting layer stacked along a direction away from the substrate. The hole injection layer and the hole transport layer are disconnected at the edge of the second conductive layer. Preferably, the light-emitting functional layer further includes an electron transport layer and an electron injection layer located on the side of the light-emitting layer away from the substrate, wherein the electron transport layer is located between the electron injection layer and the light-emitting layer.

15. A display device, characterized in that, Includes the display panel as described in any one of claims 1 to 12.

Images