Display Panel Encapsulation Structure Without Metal Mask Defects
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Solution Overview
Problem
Existing display panels face issues with durability and reliability, particularly in organic light-emitting display panels, due to the use of metal masks which can lead to defects and inefficiencies in manufacturing.
Innovation Solution
A display panel design that forms light-emitting elements without using a metal mask, incorporating a base layer, pixel defining film, bank layer, light-emitting elements, dummy patterns, and inorganic encapsulation patterns, along with an organic and inorganic film structure to enhance durability and prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal mask is used to form light-emitting elements, then the manufacturing process can be simplified, but defects occur and reliability deteriorates
Solution Approach 1:
The patent removes the metal mask from the manufacturing process entirely. Instead of using a metal mask to define pixel patterns, the invention uses a bank layer with pixel openings that directly exposes the substrate areas where light-emitting elements will be formed. This extraction of the problematic metal mask component eliminates the source of defects while maintaining manufacturing feasibility through alternative patterning methods.
Solution Approach 2:
The patent introduces a bank layer as an intermediary structure between the pixel-defining layer and the substrate. This bank layer serves as a mediator that defines pixel openings to expose specific substrate areas, eliminating the need for direct metal mask contact with internal structures. The bank layer acts as a protective and defining intermediary that prevents defects while enabling precise pixel formation.
2Ease of manufacture
If a metal mask is used in the manufacturing process, then patterning can be achieved, but manufacturing precision deteriorates due to defect occurrence
Solution Approach 1:
The invention extracts and removes the metal mask from the patterning process. Instead of relying on metal mask precision, the patent uses a bank layer with pixel openings that directly defines the pixel boundaries on the substrate. This approach eliminates mask-related precision issues while maintaining the ability to create precise pixel patterns through the bank layer geometry and opening configuration.
Solution Approach 2:
The patent uses a pixel-defining layer that copies or replicates the desired pixel pattern directly onto the bank layer structure. This copying mechanism transfers the pixel design without requiring metal mask intervention, thereby achieving precise patterning through the bank layer's geometric definition rather than through mask fabrication and alignment.
3Productivity
If metal masks are used, then the manufacturing process can be completed, but durability is reduced due to defect occurrence
Solution Approach 1:
The patent extracts the metal mask component that causes durability issues. By removing the metal mask and using a bank layer with pixel openings instead, the invention eliminates the source of defects that compromise durability. The manufacturing process remains completeable through this alternative approach, but the resulting display panel achieves improved durability and reliability without mask-related defects.
Solution Approach 2:
The bank layer serves as a protective intermediary that prevents direct exposure of internal structures to contaminants and defects. This intermediary structure protects the light-emitting elements and underlying layers during manufacturing and operation, thereby improving durability while still enabling complete manufacturing through the pixel opening design.
Data Source
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AI summary
A display panel includes a base layer, a pixel defining film disposed on the base layer and including an inorganic material, a bank layer which is disposed on the pixel defining film and in which a plurality of pixel openings is defined, a plurality of light-emitting elements disposed in each of the plurality of pixel openings and including an anode, a light-emitting pattern, and a cathode. The cathode contacts the bank layer, a dummy pattern is disposed on the bank layer, an inorganic encapsulation pattern is disposed on the cathode and includes a portion disposed on the dummy pattern, an organic pattern is disposed on the inorganic encapsulation pattern, and an inorganic film is disposed on the organic pattern. A portion of the inorganic film is disposed between the dummy pattern and the bank layer.