Display Panel Encapsulation Geometry for Electrode Overlap
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Solution Overview
Problem
Existing display panels face issues where the second electrode of the light-emitting unit struggles to effectively overlap with the isolation structure due to the encapsulation layer remaining on the side wall, affecting the display effect.
Innovation Solution
The encapsulation layer on the side wall of the isolation structure corresponding to the second light-emitting unit is side-etched, ensuring the taper angles of the encapsulation units for different light-emitting units are not equal, allowing the second electrodes to overlap with the isolation structure effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the encapsulation layer is formed uniformly on all side walls of the isolation structure, then the manufacturing process is simple and consistent, but the second electrode cannot effectively overlap with the isolation structure, degrading display effect
Solution Approach 1:
The patent applies asymmetry by making the encapsulation units have different taper angles on different sides. Specifically, the encapsulation unit has a first taper angle on the side facing the first light-emitting unit and a second taper angle on the side facing the second light-emitting unit, where these angles are different. This asymmetric design enables the second electrode to effectively overlap with the isolation structure while maintaining proper encapsulation, thereby resolving the contradiction between manufacturing precision and device complexity.
Solution Approach 2:
The patent applies local quality by giving different geometric characteristics to different portions of the encapsulation layer. The encapsulation units have different taper angles depending on their location relative to different light-emitting units. This localized differentiation allows each region of the encapsulation layer to be optimized for its specific function, enabling effective electrode overlap in the second light-emitting unit region while maintaining encapsulation integrity throughout.
2Manufacturing precision
If the taper angle of encapsulation units is made unequal for different light-emitting units, then the second electrode can overlap with the isolation structure effectively, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by pre-designing the encapsulation units with different taper angles during the encapsulation layer formation process. The asymmetric taper angles are built into the encapsulation units from the beginning, allowing subsequent electrode deposition to proceed effectively. This preliminary geometric configuration enables effective electrode overlap without requiring complex post-processing or adjustment steps.
Solution Approach 2:
The patent applies parameter changes by varying the taper angle parameter of the encapsulation units based on their location. The first taper angle and second taper angle are different, allowing optimization of electrode overlap for each light-emitting unit. This parameter differentiation is achieved through controlled deposition conditions during encapsulation layer formation, balancing manufacturing feasibility with performance requirements.
3Reliability
If the encapsulation layer completely covers the side walls of the isolation structure, then protection is maximized, but the second electrode overlap with isolation structure is hindered
Solution Approach 1:
The patent applies curvature principles by designing the encapsulation units with tapered sides rather than vertical walls. The encapsulation units have inclined surfaces that create a gradual transition, allowing the second electrode to overlap with the isolation structure while still maintaining protective coverage. The curved/tapered geometry enables both protection and effective electrode overlap simultaneously.
Data Source
AI summary
A display panel includes an array substrate, an isolation structure, a light-emitting unit, and a first encapsulation layer. The isolation structure encloses and forms an isolation opening. At least part of a light-emitting unit is located in the isolation opening. The light-emitting unit includes a first light-emitting unit and a second light-emitting unit. The first encapsulation layer is located on a side of the light-emitting unit away from the array substrate. The first encapsulation layer includes a plurality of encapsulation units spaced apart. The encapsulation units extend from a side surface of the isolation structure to a side of the isolation structure away from the array substrate.