Display module, preparation method thereof and display device
Patent Information
- Application Number
- CN202510552170.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-28
- Publication Date
- 2026-10-30
AI Technical Summary
[0003]但目前的OLED显示产品的使用性能有待提升
[0031]本申请提供的显示模组，通过在光学胶层采用不同折射率材料形成第一调光层41和第二调光层42，第一调光层41和第二调光层42的交界处采用微结构设计，能够调控光场方向，避免无序散射导致的闪点问题。可以省去传统LCF膜及部分粘接层，能够减小显示模组的厚度，适配轻薄化需求。
Smart Images
Figure CN123021966A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of display technology, and in particular to a display module, its manufacturing method, and a display device. Background Technology
[0002] Organic light-emitting diodes (OLEDs) and flat panel displays based on light-emitting diodes (LEDs) are widely used in various consumer electronics products such as mobile phones, televisions, laptops, and desktop computers due to their advantages such as high image quality, energy saving, thin body, and wide range of applications, becoming the mainstream of display devices.
[0003] However, the performance of current OLED display products needs to be improved. Summary of the Invention
[0004] In view of this, the purpose of this application is to provide a display module and its manufacturing method, as well as a display device, which aims to improve the light emission effect and enhance the performance of OLED display products.
[0005] To achieve the above objectives, the first aspect of this application provides a display module, comprising:
[0006] substrate;
[0007] The display functional layer is disposed on one side of the substrate and includes a plurality of light-emitting units;
[0008] An encapsulation layer is disposed on the side of the display functional layer away from the substrate, and the orthographic projection of the light-emitting unit on the substrate is located within the orthographic projection of the display functional layer on the substrate;
[0009] A cover plate, the cover plate being disposed on the side of the encapsulation layer away from the substrate;
[0010] An optical adhesive layer is disposed between the encapsulation layer and the cover plate; the optical adhesive layer includes a first dimming layer and a second dimming layer, the second dimming layer is disposed on the side of the first dimming layer away from the substrate, the first dimming layer and the second dimming layer have different refractive indices, and a first microstructure is formed at the junction of the first dimming layer and the second dimming layer; the first microstructure is used to converge at least a portion of the light emitted by the light-emitting unit toward the center of the light-emitting unit.
[0011] Optionally, the first dimming layer includes a plurality of first protrusions spaced apart, and the second dimming layer includes a second substrate and a plurality of second protrusions spaced apart; the first protrusions protrude in a direction away from the substrate, and the second protrusions protrude on the second substrate in a direction closer to the substrate; the plurality of first protrusions and the plurality of second protrusions are alternately arranged in a direction parallel to the substrate.
[0012] Optionally, the refractive index of the first dimming layer is greater than that of the second dimming layer, and the sidewall of the first protrusion contacts the second protrusion to form a first total internal reflection interface.
[0013] Optionally, the first dimming layer includes a first substrate portion and a plurality of first protrusions spaced apart, and the second dimming layer includes a plurality of second protrusions; the first direction is parallel to the substrate, the first protrusions protrude on the first substrate portion in a direction away from the substrate, and the second protrusions protrude in a direction closer to the substrate; the plurality of first protrusions and the plurality of second protrusions are alternately arranged along a direction parallel to the substrate.
[0014] Optionally, the refractive index of the first dimming layer is less than that of the second dimming layer, and the sidewall of the second protrusion contacts the first protrusion to form a second total internal reflection interface.
[0015] Optionally, the display module further includes:
[0016] A polarizing layer is disposed between the encapsulation layer and the cover plate;
[0017] An adhesive layer is disposed between the optical adhesive layer and the polarizing layer;
[0018] And / or, the cover plate includes a second microstructure.
[0019] Optionally, the optical adhesive layer is located between the encapsulation layer and the polarizing layer; or, the optical adhesive layer is located between the polarizing layer and the cover plate.
[0020] A second aspect of this application provides a method for manufacturing a display module, the method comprising:
[0021] Provide a substrate;
[0022] A display functional layer is provided on one side of the substrate, and multiple light-emitting units are formed in the display functional layer;
[0023] An encapsulation layer is provided on the side of the display functional layer away from the substrate, and the orthographic projection of the light-emitting unit on the substrate is located within the orthographic projection of the display functional layer on the substrate;
[0024] A first dimming layer and a second dimming layer are formed by vapor deposition of materials with different refractive indices on the side of the encapsulation layer away from the substrate. The second dimming layer is located on the side of the first dimming layer away from the substrate and forms an optical adhesive layer with the first dimming layer. A first microstructure is formed at the junction of the first dimming layer and the second dimming layer. The first microstructure is used to make at least a portion of the light emitted by the light-emitting unit converge toward the center of the light-emitting unit.
[0025] A cover plate is provided on the side of the optical adhesive layer away from the substrate.
[0026] Optionally, the process of forming a first dimming layer and a second dimming layer by vapor deposition of materials with different refractive indices on the side of the encapsulation layer away from the substrate includes:
[0027] A high refractive index material is coated on the side of the encapsulation layer away from the substrate;
[0028] The first dimming layer is formed by an exposure process using a mask and an etching process to form a plurality of spaced first protrusions, with the first direction being parallel to the substrate.
[0029] A low-refractive-index material is coated on the side of the first dimming layer away from the substrate to form a second dimming layer, which covers the first protrusion and fills the gap between adjacent first protrusions.
[0030] An embodiment of the third aspect of this application provides a display device, including a display module of any of the above embodiments, or a display module prepared by the preparation method of the display module of any of the above embodiments.
[0031] The display module provided in this application uses materials with different refractive indices to form a first dimming layer 41 and a second dimming layer 42 in the optical adhesive layer. A microstructure design is employed at the junction of the first dimming layer 41 and the second dimming layer 42, which enables the control of the light field direction and avoids flash point problems caused by disordered scattering. This eliminates the need for traditional LCF films and some adhesive layers, reducing the thickness of the display module and meeting the requirements for thinner and lighter designs. Attached Figure Description
[0032] 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.
[0033] Figure 1 This is a schematic diagram of the film layer structure of a related display module;
[0034] Figure 2 This is a schematic diagram of the film structure of another related display module;
[0035] Figure 3 This is a schematic diagram of the film layer structure of a display module provided in an embodiment of this application;
[0036] Figure 4 This is a partial structural diagram of a microstructure in a display module provided in an embodiment of this application;
[0037] Figure 5 This is a schematic diagram of the film layer structure of a display module provided in another embodiment of this application;
[0038] Figure 6 This is a schematic diagram of the film layer structure of a display module provided in another embodiment of this application;
[0039] Figure 7 This is a schematic diagram of the film layer structure of a display module encapsulation layer provided in an embodiment of this application;
[0040] Figure 8 A schematic flowchart illustrating a method for manufacturing a display module according to an embodiment of this application;
[0041] Figure 9 This is a schematic diagram of the film structure during the fabrication process of a display module, as provided in an embodiment of this application.
[0042] Marker explanation:
[0043] 100. Display module; 1. Substrate; 2. Display functional layer; 20. Light-emitting unit; 3. Encapsulation layer; 31. First sub-encapsulation layer; 32. Second sub-encapsulation layer; 33. Third sub-encapsulation layer; 34. Touch sub-encapsulation layer; 4. Optical adhesive layer; 41. First dimming layer; 410. First substrate; 411. First protrusion; 42. Second dimming layer; 420. Second substrate; 421. Second protrusion; 5. Cover plate; 6. Polarizing layer; 7. Adhesive layer; 8. Light control film; 9. Mask plate. Detailed Implementation
[0044] 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.
[0045] 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.
[0046] 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.
[0047] 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.
[0048] With the increasing popularity of medium-sized mobile devices such as tablets and laptops in the field of learning, display terminal manufacturers are paying more and more attention to eye protection functions.
[0049] Figure 1 This is a schematic diagram of the film layer structure of a related display module. For example... Figure 1As shown, in a related technology, a display module 100 includes a stacked display functional layer 2, an adhesive layer 7, and a cover plate 5. The display functional layer 2 includes multiple light-emitting units 20. However, the specular reflection on the surface of the cover plate 5 of the display module 100 easily causes glare, which significantly reduces the visibility of the display module 100 and has a long-term impact on eye health. Therefore, microstructures are formed on the surface of the cover plate 5. Specifically, a micron-level uneven structure is formed on the surface of the cover plate 5 to form an anti-glare (AG) cover plate, which can convert specular reflection into diffuse reflection, thereby reducing glare. However, AG treatment of the cover plate surface can cause other problems, typically an optical defect known as sparkle. Sparkle is a phenomenon where the human eye observes unevenly distributed colored dots on a display screen. AG treatment makes the surface of the cover plate 5 irregularly undulating, causing uneven scattering of light emitted by pixels on the textured surface, resulting in uneven distribution of light intensity and color. Users can see sparkle when viewing the display screen. That is, the disordered scattering of light from the screen creates visual noise, affecting the display effect.
[0050] Figure 2 This is a schematic diagram of the film layer structure of another related display module. (Example) Figure 2 As shown, in another related technology, the display module 100 includes a display functional layer 2, an adhesive layer 7, a light-controlling film 8, and a cover plate 5 stacked together. The light-controlling film 8 is an LCF (Light Control Film), which can regulate the direction of the light field. However, it suffers from the following problems: supply chain issues, as LCF films rely on imports, resulting in long procurement cycles (≥100 days), high costs, and insufficient supplier capacity; process limitations, as the thickness of the LCF film (approximately 85μm) is difficult to compress, failing to meet the demand for thinner and lighter designs; and resolution bottlenecks, as the pitch of the LCF film is difficult to reduce, making it incompatible with high PPI (pixel density) display modules.
[0051] Based on this, this application provides a solution for a display module that achieves anti-glare and anti-flicker functions through screen process optimization without relying on LCF film, while reducing costs, thinning the module and adapting to high resolution requirements.
[0052] The display module 100 of this application may include an OLED display panel, a quantum dot light-emitting diode (QLED) display panel, etc. OLED display panels have advantages such as small size, portability, flexibility, and narrow bezels, and are increasingly used in high-performance display fields. The following embodiments of this application are all explained using the display module 100 including an OLED display panel as an example. Furthermore, when the substrate in the OLED display panel is made of a flexible substrate material, the OLED display panel can be a flexible display panel. The following embodiments of this application are all explained using the OLED display panel as a flexible display panel as an example. It should be noted that the aforementioned flexible substrate material may include one or more of polyethylene terephthalate (PET), polyethylene naphthalate (PEN), or polyimide (PI), etc., and the embodiments of this application do not limit this.
[0053] Figure 3 This is a schematic diagram of the film layer structure of a display module provided in an embodiment of this application; Figure 4 This is a partial structural diagram of a microstructure in a display module provided in an embodiment of this application. For example... Figure 3 , Figure 4 As shown, an embodiment of the first aspect of this application provides a display module 100, which includes a substrate 1, a display functional layer 2, an encapsulation layer 3, an optical adhesive layer 4, and a cover plate 5.
[0054] The display functional layer 2 is disposed on one side of the substrate 1 and includes multiple light-emitting units 20. An encapsulation layer 3 is disposed on the side of the display functional layer 2 away from the substrate 1, and the orthographic projection of the light-emitting units 20 onto the substrate 1 lies within the orthographic projection of the display functional layer 2 onto the substrate 1. A cover plate 5 is disposed on the side of the encapsulation layer 3 away from the substrate 1. An optical adhesive layer 4 is disposed between the encapsulation layer 3 and the cover plate 5; the optical adhesive layer 4 includes a first dimming layer 41 and a second dimming layer 42, the second dimming layer 42 being disposed on the side of the first dimming layer 41 away from the substrate 1, the first dimming layer 41 and the second dimming layer 42 having different refractive indices, and a first microstructure forming at the junction of the first dimming layer 41 and the second dimming layer 42; the first microstructure is used to converge at least a portion of the light emitted by the light-emitting units 20 towards the center of the light-emitting units 20.
[0055] The display module 100 provided in this application embodiment forms a first dimming layer 41 and a second dimming layer 42 using materials with different refractive indices. The junction of the first dimming layer 41 and the second dimming layer 42 adopts a microstructure design, which can control the direction of the light field and avoid the flash point problem caused by disordered scattering. It can eliminate the need for the traditional LCF film and part of the adhesive layer 7, thereby reducing the thickness of the display module and meeting the requirements for thinner and lighter designs.
[0056] Exemplarily, substrate 1 is used to support display functional layer 2. Display functional layer 2 includes multiple light-emitting units 20, such as OLED or Micro-LED pixels, which can be formed on the surface of substrate 1 by vapor deposition. Encapsulation layer 3 can employ thin-film encapsulation (TFE) technology, such as alternating vapor deposition of inorganic and organic layers, to cover display functional layer 2 and isolate it from water and oxygen corrosion. Optical adhesive layer 4 is located between encapsulation layer 3 and cover plate 5, and is formed by stacking a first dimming layer 41 and a second dimming layer 42, with a first microstructure formed at the junction of the two. The first microstructure can be a periodic concave-convex structure or a prism structure, which converges the wide-angle light from the light-emitting units 20 towards the center through the principle of total internal reflection.
[0057] Specifically, the first microstructure modulates light through the interface between high and low refractive index materials. For example, when light enters a low refractive index material (such as acrylic resin) from a high refractive index material (such as silicon-based material), large-angle light is forced into total internal reflection (similar to specular reflection), thus pulling the light that might otherwise scatter in all directions back to the central display area, reducing flickering issues caused by disordered scattering. In other words, the microstructure, through orderly arrangement (such as periodic concavity and convexity), allows light to converge to a specific angle before reaching the cover plate, essentially creating a light guide to avoid disordered scattering. This light path guidance makes the display clearer and more eye-friendly.
[0058] During fabrication, a substrate 1 is first prepared, and a display functional layer 2 is set on one side of it. Multiple light-emitting units 20 are fabricated in the display functional layer 2 using semiconductor processes such as photolithography and etching. The layout and structure of the light-emitting units 20 are determined according to the design requirements of the display module 100. An encapsulation layer 3 is set on the side of the display functional layer 2 away from the substrate 1. Its function is to protect the display functional layer 2 from external moisture, impurities, etc. It can be formed by coating or vapor deposition using organic or inorganic materials. Then, an optical adhesive layer 4 is set on the side of the encapsulation layer 3 away from the substrate 1. The optical adhesive layer 4 consists of a first dimming layer 41 and a second dimming layer 42. Using a vapor deposition process, a material with a different refractive index is first vapor deposited to form the first dimming layer 41, and then a material with a different refractive index is vapor deposited on the side away from the substrate 1 to form the second dimming layer 42. A first microstructure is naturally formed at the interface between the two. Finally, a cover plate 5 is set on the side of the optical adhesive layer 4 away from the substrate 1. The cover plate 5 can be made of transparent materials such as glass and is fixed to the optical adhesive layer 4 by a bonding process. The first microstructure at the interface of the first dimming layer 41 and the second dimming layer 42 of the optical adhesive layer 4, with their different refractive indices, alters the propagation direction of light emitted from the light-emitting unit 20, causing the light to converge towards the center of the light-emitting unit 20. In actual displays, light emitted from the display module would normally be scattered due to the microstructure of the cover plate, leading to flashing and affecting the display effect. This structure, however, ensures more orderly light propagation, reducing scattering and random reflections, thereby lowering the probability of flashing and improving display quality. Furthermore, the structural design of this application does not rely on LCF film, avoiding problems such as long procurement lead times, high prices, supply shortages, and inability to meet the requirements of high-end high-definition display modules and thin-and-light designs. For example, the module thickness can be reduced from 85μm to below 50μm, adapting to the demand for thinner and lighter designs. This also reduces module costs, enhances the product's market competitiveness, and the high maturity of the process lowers the entry barrier, facilitating large-scale production.
[0059] like Figure 3 , Figure 4 As shown, in some embodiments, the first dimming layer 41 includes a plurality of first protrusions 411 spaced apart, and the second dimming layer 42 includes a second substrate 420 and a plurality of second protrusions 421 spaced apart. A first direction is parallel to the substrate 1, the first protrusions 411 protrude in a direction away from the substrate 1, and the second protrusions 421 protrude on the second substrate 420 in a direction closer to the substrate 1; along a direction parallel to the substrate 1, the plurality of first protrusions 411 and the plurality of second protrusions 421 are alternately arranged.
[0060] Furthermore, the refractive index of the first dimming layer 41 is greater than that of the second dimming layer 42, and the sidewall of the first protrusion 411 contacts the second protrusion 421 to form a first total internal reflection interface.
[0061] For example, the first dimming layer 41 is made of a high-refractive-index material, such as a silicon-based nanocomposite material with a refractive index of 1.7; the second dimming layer 42 is made of a low-refractive-index material, such as an acrylic resin with a refractive index of 1.4.
[0062] The alternating arrangement of multiple first protrusions 411 and second protrusions 421 increases the area and frequency of refraction and reflection of light at the interfaces of materials with different refractive indices. When light is emitted from the light-emitting unit 20 and encounters the alternating structure of the first protrusions 411 and second protrusions 421, it continuously changes its propagation direction, more effectively converging towards the center of the light-emitting unit 20. This allows for more precise control of the light path, further reducing light scattering and improving display clarity and uniformity. Simultaneously, this structural design is more advantageous in meeting the requirements of thinner modules. The design of the first protrusions 411 and second protrusions 421 can reduce the amount of material used while ensuring optical performance, achieving a thinner and lighter module, which aligns with the development trend of thinner and lighter electronic devices.
[0063] When the refractive index of the first dimming layer 41 is greater than that of the second dimming layer 42, materials with suitable refractive indices are selected for vapor deposition of the first dimming layer 41 and the second dimming layer 42 during the manufacturing process. After the first protrusion 411 and the second protrusion 421 are formed, a first total internal reflection interface will naturally form on their sidewalls due to their close contact. During the vapor deposition process, the thickness of the material and the vapor deposition conditions are precisely controlled to ensure the dimensional and positional accuracy of the first protrusion 411 and the second protrusion 421, thereby guaranteeing the quality and stability of the first total internal reflection interface. The formation of the first total internal reflection interface greatly enhances the light converging effect. According to optical principles, when light travels from the optically denser medium of the first dimming layer 41 to the optically less dense medium of the second dimming layer 42, total internal reflection occurs at a specific angle. In this display module, the first total internal reflection interface causes light with a wide viewing angle to undergo total internal reflection at the interface, changing its propagation direction and converging towards the center of the light-emitting unit 20. This total internal reflection effect effectively collects and converges light that might otherwise be scattered, further reducing light loss and random reflections. This makes the light emitted by the display module more concentrated and uniform, significantly improving the display effect and effectively solving the flicker problem. At the same time, the design utilizing the principle of total internal reflection improves optical performance and enhances the product's cost-effectiveness without increasing material and process complexity.
[0064] Figure 5 This is a schematic diagram of the film layer structure of a display module provided in another embodiment of this application. Figure 5As shown, in some other embodiments, the first dimming layer 41 includes a first substrate portion 410 and a plurality of first protrusions 411 spaced apart, and the second dimming layer 42 includes a plurality of second protrusions 421; the first direction is parallel to the substrate 1, the first protrusions 411 protrude on the first substrate portion 410 in a direction away from the substrate 1, and the second protrusions 421 protrude in a direction close to the substrate 1; along a direction parallel to the substrate 1, the plurality of first protrusions 411 and the plurality of second protrusions 421 are alternately arranged.
[0065] Furthermore, the refractive index of the first dimming layer 41 is less than that of the second dimming layer 42, and the sidewall of the second protrusion 421 contacts the first protrusion 411 to form a second total internal reflection interface.
[0066] When fabricating the first dimming layer 41, a first body portion 410 is first formed, which can be obtained by coating a material and performing a planarization process. Then, first protrusions 411 are formed on the first body portion 410 by photolithography and etching processes, which are spaced apart along the first direction and protrude in a direction away from the substrate 1. When fabricating the second dimming layer 42, after the first dimming layer 41 is fabricated, a corresponding material is coated to form a plurality of second protrusions 421 that protrude in a direction close to the substrate 1, so that the plurality of first protrusions 411 and the plurality of second protrusions 421 are alternately arranged in a direction parallel to the substrate 1.
[0067] The alternating arrangement of multiple first protrusions 411 and second protrusions 421 increases the opportunities for light refraction and reflection, allowing the light to converge better towards the center of the light-emitting unit 20. However, the structural forms of the first dimming layer 41 and the second dimming layer 42 are different in this structure. In some applications, this structure may be easier to implement or achieve better optical effects under specific display requirements. For example, in cases with special requirements for display viewing angles, this structure can more flexibly control the direction of light propagation by adjusting the size, spacing, and shape of the first protrusions 411 and the second protrusions 421, thereby meeting different display needs, further improving product applicability, and solving the flicker problem in different scenarios. The presence of the second total internal reflection interface further enhances the light-converging ability. When light travels from the optically less dense medium of the first dimming layer 41 to the optically denser medium of the second dimming layer 42, total internal reflection occurs at a suitable angle, causing the light to change its propagation direction and converge towards the center of the light-emitting unit 20. This total internal reflection mechanism can more effectively control the propagation of light, reduce light scattering and loss, improve the brightness and contrast of the display module, further optimize the display effect, and more effectively solve the flicker problem. Moreover, this structural design based on the principle of total internal reflection improves display performance without increasing costs or manufacturing complexity, which is conducive to the large-scale production and promotion of the product.
[0068] Furthermore, the interchangeable high- and low-refractive-index materials allow for adaptation to the light-emitting characteristics of different display modules. Microstructures can limit the total internal reflection angle to within ±30°, improving light intensity distribution uniformity by 30%. Through mask fabrication, the spacing between adjacent first protrusions 411 can be compressed to 5μm, meeting the requirements of high-resolution 4K / 8K displays.
[0069] Figure 6 This is a schematic diagram of the film layer structure of a display module provided in another embodiment of this application. For example... Figure 6 As shown, in some embodiments, the display module 100 further includes a polarizing layer 6 and an adhesive layer 7. The polarizing layer 6 is disposed between the encapsulation layer 3 and the cover plate 5. The adhesive layer 7 is disposed between the optical adhesive layer 4 and the polarizing layer 6. The optical adhesive layer 4 is located between the encapsulation layer 3 and the polarizing layer 6.
[0070] Specifically, the encapsulation layer 3, polarizing layer 6, adhesive layer 7, optical adhesive layer 4, and cover plate 5 are sequentially stacked in a direction away from the substrate 1. The polarizing layer 6 includes a phase retardation film and a linear polarizer. The linear polarizer is located on the side of the phase retardation film away from the display functional layer 2, and the linear polarizer only allows light with a vibration direction parallel to the optical axis of the linear polarizer to pass through. The phase retardation film can be a quarter-wavelength phase retardation film, and the angle between the optical axis of the linear polarizer and the optical axis of the phase retardation film is 45°.
[0071] like Figure 5 As shown, in some embodiments, the optical adhesive layer 4 is located between the polarizing layer 6 and the cover plate 5. Specifically, the encapsulation layer 3, the optical adhesive layer 4, the adhesive layer 7, the polarizing layer 6, and the cover plate 5 are stacked sequentially in a direction away from the substrate 1.
[0072] The polarizing layer 6 controls the polarization direction of light, reducing ambient light reflection and interference, and further improving display clarity and viewing angle. In practical applications, ambient light reflection affects display performance; the polarizing layer 6 filters out some reflected light, making the displayed content clearer. The adhesive layer 7 ensures a strong connection between the polarizing layer 6 and other components, guaranteeing the structural stability of the entire display module.
[0073] In some embodiments, the cover plate 5 includes a second microstructure. The second microstructure on the cover plate 5 can work synergistically with the first microstructure of the optical adhesive layer 4 to further optimize the propagation and scattering of light, enhance anti-glare capability, better solve the flash point problem, improve display quality, and meet users' higher requirements for display effects.
[0074] Specifically, the cover plate 5 can be a flat cover plate, such as a glass cover plate, which can provide protection to the polarizing layer 6, the display functional layer 2 and other film layers, thereby improving the service life of the display module 100.
[0075] By setting the polarizing layer 6, reflected light from external ambient light can be prevented from entering the display module, thus ensuring the display performance of the display module. For example, the polarizing layer 6 is an elliptical polarizer used to eliminate the influence of external light on the displayed image.
[0076] Specifically, there are two options for the location of the optical adhesive layer 4. If the optical adhesive layer 4 is located between the encapsulation layer 3 and the polarizing layer 6, during the manufacturing process, the substrate 1, display functional layer 2, encapsulation layer 3, and optical adhesive layer 4 are fabricated using the method described above. Then, the polarizing layer 6 is bonded to the side of the optical adhesive layer 4 away from the substrate 1 using the adhesive layer 7. Finally, a cover plate 5 is placed on the side of the polarizing layer 6 away from the substrate 1. If the optical adhesive layer 4 is located between the polarizing layer 6 and the cover plate 5, the substrate 1, display functional layer 2, encapsulation layer 3, and polarizing layer 6 are fabricated first. Then, the optical adhesive layer 4 is placed on the side of the polarizing layer 6 away from the substrate 1 using the adhesive layer 7. Finally, a cover plate 5 is placed on the side of the optical adhesive layer 4 away from the substrate 1. The different locations of the optical adhesive layer 4 can be selected according to different display module design requirements and optical performance requirements. When the optical adhesive layer 4 is located between the encapsulation layer 3 and the polarizing layer 6, this structure allows the optical adhesive layer 4 to perform preliminary dimming and focusing of the light before it passes through the polarizing layer 6 for polarization. In display modules with specific requirements for dimming and polarization sequence, this structure can work together better to improve the display effect. When the optical adhesive layer 4 is located between the polarizing layer 6 and the cover plate 5, the polarizing layer 6 can first polarize the light to reduce ambient light interference, and then the optical adhesive layer 4 further focuses and optimizes the light. This structure is advantageous in display modules that emphasize anti-glare and dimming effects, and can more effectively solve the flicker problem, improve display clarity and stability, and meet the design requirements of different products.
[0077] In some embodiments, the light-emitting unit 20 includes a first electrode, a light-emitting functional layer, and a second electrode sequentially stacked along a direction away from the substrate 1. Specifically, the light-emitting unit 20 includes a first electrode, a light-emitting functional layer, and a second electrode stacked sequentially. The first electrode is an anode, and the second electrode is a cathode. For example, the light-emitting functional layer may include a light-emitting layer, and may further include one or more of a hole injection layer, a hole transport layer, an organic light-emitting functional layer, an electron transport layer, and an electron injection layer, and may even further include one or more of a hole blocking layer and an electron blocking layer.
[0078] Figure 7 This is a schematic diagram of the film layer structure of a display module encapsulation layer provided in an embodiment of this application. Figure 7As shown, in some embodiments, the encapsulation layer 3 includes a first sub-encapsulation layer 31, a second sub-encapsulation layer 32, a third sub-encapsulation layer 33 and a touch sub-encapsulation layer 34, which are sequentially stacked along a direction away from the substrate 1. The first sub-encapsulation layer 31 includes inorganic materials, the second sub-encapsulation layer 32 includes organic materials, and the third sub-encapsulation layer 33 includes inorganic materials.
[0079] The encapsulation layer 3 is located on the side of the display functional layer 2 away from the substrate 1 to prevent water and oxygen intrusion and protect the display functional layer 2. The encapsulation layer 3 may include stacked inorganic and organic materials. Compared with organic materials, inorganic material layers have better water and oxygen barrier capabilities; compared with inorganic materials, organic materials have better flexibility and better film-forming properties. By encapsulating the display functional layer 2 together with organic and inorganic materials, the overall water and oxygen resistance capability of the display module 100 is improved.
[0080] In some embodiments, the substrate 1 includes an SCF (Super Clean Foam) assembly, which includes an adhesive layer, a buffer layer, and a metal layer stacked sequentially. The adhesive layer is used to bond the buffer layer and the display functional layer 2. The buffer layer enhances the impact resistance of the display module 100, and the metal layer increases the strength and toughness of the display module 100, thereby increasing its drop resistance and further enhancing the protection of the display functional layer 2. The buffer layer is made of a material that is elastic, lightweight, flexible, and ultra-thin, such as foam. The metal layer is made of a highly ductile metal, such as copper foil.
[0081] Figure 8 This is a schematic flowchart illustrating a method for fabricating a display module according to an embodiment of this application. Figure 8 As shown, an embodiment of the second aspect of this application also provides a method for manufacturing a display module. The method for manufacturing the display module 100 includes the following steps:
[0082] Step S1: Provide a substrate 1;
[0083] Step S2: A display functional layer 2 is provided on one side of the substrate 1, and multiple light-emitting units 20 are formed on the display functional layer 2;
[0084] Step S3: An encapsulation layer 3 is provided on the side of the displayed functional layer 2 away from the substrate 1, and the orthographic projection of the light-emitting unit 20 on the substrate 1 is located within the orthographic projection of the displayed functional layer 2 on the substrate 1.
[0085] Step S4: On the side of the encapsulation layer 3 away from the substrate 1, materials with different refractive indices are vapor-deposited to form a first dimming layer 41 and a second dimming layer 42. The second dimming layer 42 is located on the side of the first dimming layer 41 away from the substrate 1 and forms an optical adhesive layer 4 with the first dimming layer 41. A first microstructure is formed at the junction of the first dimming layer 41 and the second dimming layer 42. The first microstructure is used to converge at least part of the light emitted by the light-emitting unit 20 toward the center of the light-emitting unit 20.
[0086] Step S5: Set a cover plate 5 on the side of the optical adhesive layer 4 away from the substrate 1.
[0087] Specifically, the fabrication method of the display module 100 includes substrate processing, display functional layer deposition, thin-film encapsulation, high- and low-fold material evaporation, and cover plate bonding. Evaporation is used instead of traditional imprinting / UV alignment, reducing the thickness to below 50μm and improving the spacing accuracy to ±0.5μm. This eliminates the need for imported LCF film, increases material utilization by 20%, and reduces overall cost by 30%. The mask process supports dynamic adjustment of the spacing of protrusions in the microstructure, meeting the requirements of high PPI displays.
[0088] The method for fabricating the display module 100 provided in this application embodiment uses an evaporation process to form the optical adhesive layer 4, which has significant advantages over traditional mold imprinting or UV alignment processes. The evaporation process allows for thinner film layers, aligning with the trend of module thinning and meeting the demand for lighter and thinner electronic devices. Simultaneously, the evaporation process has fewer limitations, enabling more precise control over the dimensions of the microstructures. This allows for smaller spacing between the protrusions of the first dimming layer 41, which is beneficial for improving the resolution and display quality of the display module. Furthermore, the evaporation process is technologically mature, lowering the process entry barrier, reducing module costs, and improving production efficiency, which is conducive to large-scale production and ensures the performance and quality of the display module.
[0089] Figure 9 This is a schematic diagram of the film layer structure during the fabrication process of a display module, as provided in an embodiment of this application. Figure 9 As shown, in some embodiments, in step S4, a first dimming layer 41 and a second dimming layer 42 are formed on the side of the encapsulation layer 3 away from the substrate 1 by vapor deposition of materials with different refractive indices, including the following specific sub-steps:
[0090] Step S41: Coat the side of the encapsulation layer 3 away from the substrate 1 with a high refractive index material;
[0091] Step S42: Exposure is performed using a mask 9, and a plurality of first protrusions 411 are formed by etching process to form a first dimming layer 41, with the first direction parallel to the substrate 1.
[0092] Step S43: A low refractive index material is coated on the side of the first dimming layer 41 away from the substrate 1 to form a second dimming layer 42. The second dimming layer 42 covers the first protrusion 411 and fills the gap between adjacent first protrusions 411.
[0093] Specifically, a high-refractive-index material (HOC) is coated on the surface of the encapsulation layer 3, and a first protrusion 411 is formed by exposure and development using a photomask; after etching, a low-refractive-index material (LOC) is coated to fill the gaps and form a second dimming layer 42.
[0094] For example, the process of forming the first dimming layer 41 and the second dimming layer 42 on the side of the encapsulation layer 3 away from the substrate 1 is as follows: First, a high refractive index material is coated, which can be done by spin coating, spraying, etc., to ensure that the material is uniformly covered on the encapsulation layer 3. Then, a mask is used for exposure processing. According to the designed pattern, the parts of the material that need to be retained are exposed. Then, the unexposed material is removed by etching, forming a plurality of first protrusions 411 spaced apart along the first direction, thereby obtaining the first dimming layer 41. Next, a low refractive index material is coated on the side of the first dimming layer 41 away from the substrate 1. A method similar to that used for coating the low refractive index material can be used to cover the first protrusions 411 and fill the gaps between adjacent first protrusions 411, forming the second dimming layer 42. In this way, the structure and performance of the first dimming layer 41 and the second dimming layer 42 can be precisely controlled. Through mask exposure and etching processes, the shape, size and spacing of the first protrusions 411 can be accurately manufactured, ensuring the structural accuracy of the first dimming layer 41. Subsequent coating with a low-refractive-index material fills the gaps and covers the first protrusion 411, forming a second dimming layer 42 that fits tightly with the first dimming layer 41. This ensures the effective formation of the first microstructure at their interface, thereby guaranteeing that light can converge as designed. This precise manufacturing process improves the consistency of the display module's optical performance, reduces product quality variations, further increases the product yield, and ensures the display module's ability to address flash point issues from a process detail perspective, thus enhancing product reliability and stability.
[0095] The third aspect of this application also provides a display device, which includes the display module 100 provided in the first aspect embodiment, or the display module 100 prepared by the preparation method of the display module provided in the second aspect embodiment. The display device provided in the third aspect embodiment has the beneficial effects of the display module 100 of any of the first aspect embodiments, or the beneficial effects of the preparation method of the display module of any of the second aspect embodiments.
[0096] Furthermore, the display device in the embodiments of this application can be any product or component with display function, such as a television, digital camera, mobile phone, watch, tablet computer, laptop computer, or navigator.
[0097] 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.
[0098] 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.
[0099] 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 module, characterized in that, include: substrate; The display functional layer is disposed on one side of the substrate and includes a plurality of light-emitting units; An encapsulation layer is disposed on the side of the display functional layer away from the substrate, and the orthographic projection of the light-emitting unit on the substrate is located within the orthographic projection of the display functional layer on the substrate; A cover plate, the cover plate being disposed on the side of the encapsulation layer away from the substrate; An optical adhesive layer is disposed between the encapsulation layer and the cover plate; the optical adhesive layer includes a first dimming layer and a second dimming layer, the second dimming layer is disposed on the side of the first dimming layer away from the substrate, the first dimming layer and the second dimming layer have different refractive indices, and a first microstructure is formed at the junction of the first dimming layer and the second dimming layer; the first microstructure is used to converge at least a portion of the light emitted by the light-emitting unit toward the center of the light-emitting unit.
2. The display module according to claim 1, characterized in that, The first dimming layer includes a plurality of first protrusions spaced apart, and the second dimming layer includes a second substrate and a plurality of second protrusions spaced apart; the first protrusions protrude in a direction away from the substrate, and the second protrusions protrude on the second substrate in a direction closer to the substrate; Along a direction parallel to the substrate, a plurality of first protrusions and a plurality of second protrusions are alternately arranged.
3. The display module according to claim 2, characterized in that, The refractive index of the first dimming layer is greater than that of the second dimming layer, and the sidewall of the first protrusion contacts the second protrusion to form a first total internal reflection interface.
4. The display module according to claim 1, characterized in that, The first dimming layer includes a first substrate portion and a plurality of first protrusion portions spaced apart, and the second dimming layer includes a plurality of second protrusion portions; the first direction is parallel to the substrate, the first protrusion portions protrude on the first substrate portion in a direction away from the substrate, and the second protrusion portions protrude in a direction closer to the substrate; Along a direction parallel to the substrate, a plurality of first protrusions and a plurality of second protrusions are alternately arranged.
5. The display module according to claim 4, characterized in that, The refractive index of the first dimming layer is less than that of the second dimming layer, and the sidewall of the second protrusion contacts the first protrusion to form a second total internal reflection interface.
6. The display module according to claim 1, characterized in that, The display module also includes: A polarizing layer is disposed between the encapsulation layer and the cover plate; An adhesive layer is disposed between the optical adhesive layer and the polarizing layer; And / or, the cover plate includes a second microstructure.
7. The display module according to claim 6, characterized in that, The optical adhesive layer is located between the encapsulation layer and the polarizing layer; or, the optical adhesive layer is located between the polarizing layer and the cover plate.
8. A method for manufacturing a display module, characterized in that, The method includes: Provide a substrate; A display functional layer is provided on one side of the substrate, and multiple light-emitting units are formed in the display functional layer; An encapsulation layer is provided on the side of the display functional layer away from the substrate, and the orthographic projection of the light-emitting unit on the substrate is located within the orthographic projection of the display functional layer on the substrate; A first dimming layer and a second dimming layer are formed by vapor deposition of materials with different refractive indices on the side of the encapsulation layer away from the substrate. The second dimming layer is located on the side of the first dimming layer away from the substrate and forms an optical adhesive layer with the first dimming layer. A first microstructure is formed at the junction of the first dimming layer and the second dimming layer. The first microstructure is used to make at least a portion of the light emitted by the light-emitting unit converge toward the center of the light-emitting unit. A cover plate is provided on the side of the optical adhesive layer away from the substrate.
9. The method for preparing a display module according to claim 8, characterized in that, The process of forming a first dimming layer and a second dimming layer by vapor deposition of materials with different refractive indices on the side of the encapsulation layer away from the substrate includes: A high refractive index material is coated on the side of the encapsulation layer away from the substrate; The first dimming layer is formed by an exposure process using a mask and an etching process to form a plurality of spaced first protrusions, with the first direction being parallel to the substrate. A low refractive index material is coated on the side of the first dimming layer away from the substrate to form a second dimming layer, which covers the first protrusion and fills the gap between adjacent first protrusions.
10. A display device, characterized in that, The display module includes the display module as described in any one of claims 1-7, or the display module prepared by the method described in claim 8 or 9.