Array Substrate Organic Layer Thickness Control for Flexible AMOLED Yield
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Solution Overview
Problem
The manufacturing process of flexible AMOLED panels faces issues with too-large height differences between layers, leading to a too-thin source/drain electrode layer or breakage of wires, which affects the flexibility and production yield of the display region.
Innovation Solution
An array substrate design that includes a non-organic membrane layer with defined openings, where a first organic layer fills only the first opening and does not fill the second opening, ensuring the source/drain electrode layer covers the inner wall of the second opening, and the thickness of the first organic layer is not greater than the depth of the first opening, reducing height differences between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an organic layer is formed to fill openings in the non-organic membrane layer to improve flexibility, then flexibility of the display region is improved, but height differences between layers are enlarged, resulting in a too-thin source/drain electrode layer or wire breakage
Solution Approach 1:
The patent applies local quality by making the organic layer thickness non-uniform: it is thinner in regions where openings are defined (display region) and thicker in regions where openings are not defined (non-display region). This localized thickness variation allows the organic layer to provide flexibility where needed while avoiding excessive height differences that would cause manufacturing defects in the source/drain electrode layer.
2Reliability
If the organic layer thickness is increased to ensure adequate coverage, then layer coverage is improved, but height differences between layers are enlarged, causing source/drain electrode layer problems
Solution Approach 1:
The patent implements local quality by varying the organic layer thickness according to the functional requirements of different regions. In the display region where openings are defined, the organic layer is kept thin to avoid excessive height differences. In the non-display region where openings are not defined, the organic layer is thicker to ensure adequate coverage and reliability. This spatially differentiated thickness distribution resolves the contradiction between coverage and height difference control.
Data Source
AI summary
The disclosure relates to an array substrate, a display panel, and a method of manufacturing the array substrate. The array substrate includes a substrate, and a non-organic membrane layer, a first organic layer, and a source/drain electrode layer which are sequentially disposed on the substrate. The substrate includes a display region. A first opening and a second opening are defined in the non-organic membrane layer and defined in the display region. The first organic layer fills the first opening. A thickness of the first organic layer is not greater than a depth of the first opening. The first organic layer does not fill the second opening. The source/drain electrode layer covers an inner wall of the second opening.