Array Substrate Organic Layer Alignment for Flexible Displays
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Solution Overview
Problem
In conventional display panels, the depth of a recess in areas where wires are connected increases due to an organic layer, blocking metal deposition and leading to signal transmission issues and abnormal image display.
Innovation Solution
An array substrate with a depressed surface of the interlayer insulating layer reaching the barrier layer, filled with an organic material to form an organic layer, and using a halftone mask to remove excess organic material, ensuring the organic layer's surface aligns with the interlayer insulating layer, preventing height differences and metal damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a recess is defined in a blank area of a wiring area and an organic layer is filled in the recess to enhance the force-relieving effect, then the force-relieving effect is improved, but the depth of the recess significantly increases in locations where wires are connected, blocking metal deposition and causing signal transmission issues
Solution Approach 1:
The patent applies local quality by making different parts of the recess have different depths. Specifically, the recess in the wiring area has a first depth, while the recess in the non-wiring area has a second depth that is greater than the first depth. This localized differentiation allows the organic layer to provide force-relieving effect where needed while preventing excessive depth that would block metal deposition in wire connection areas.
2Strength
If the recess depth is increased to enhance force relief, then the force-relieving effect is improved, but metals of the wires are blocked and unable to be completely deposited in the recess area
Solution Approach 1:
The patent implements local quality by creating depth differentiation in the recess structure. The recess depth is locally adjusted to be shallower in wiring areas (first depth) compared to non-wiring areas (second depth). This ensures that metal wires can be completely deposited in the wiring area recess without being blocked, while still providing adequate force-relieving effect through the organic layer filling.
Data Source
AI summary
The disclosure relates to an array substrate, a manufacturing method thereof, and a display panel. In one aspect, an organic layer is disposed in a display area to release applied forces generated when the array substrate is frequently bent. In another aspect, without adding additional mask sheets, a portion of the organic material in a recess is removed by using a halftone mask, an organic material in other areas of the display area is completely removed, and an organic material of a photoresist layer in a bending area is retained. Therefore, a surface of the organic layer away from the substrate aligns with a surface of the interlayer insulating layer away from the substrate, so that there is no height difference when a top source/drain layer is disposed.