Display Panel Partition Wall and Encapsulation Thickness
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Solution Overview
Problem
Existing display panels face challenges in achieving improved display quality, particularly in the manufacturing process without using a metal mask, which can lead to defects and reduced resolution.
Innovation Solution
A display panel design that includes a base layer, a pixel-defining film with defined light-emitting openings, a partition wall with specific openings, and light-emitting elements covered by lower inorganic encapsulation patterns of varying thicknesses, allowing for the emission of blue, green, and red light without the need for a metal mask.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a metal mask is used in the manufacturing process, then the light-emitting patterns can be formed with good precision, but the manufacturing complexity and cost increase, and defects may occur
Solution Approach 1:
The patent removes the metal mask from the manufacturing process entirely. Instead of using a metal mask to define light-emitting patterns, the invention uses a partition wall structure with openings that directly expose the light-emitting elements. This extraction of the metal mask component eliminates the associated complexity and defect risks while maintaining pattern formation precision through the partition wall geometry.
Solution Approach 2:
The partition wall serves as an intermediary structure that replaces the metal mask's function. The partition wall with defined openings provides the necessary pattern definition and structural support without requiring a separate metal mask layer, thereby simplifying the manufacturing process while maintaining precision.
2Ease of manufacture
If uniform thickness encapsulation patterns are used, then the manufacturing process is simplified, but leakage current and driving errors increase
Solution Approach 1:
The patent implements variable thickness in the lower inorganic encapsulation pattern according to the specific light-emitting element's requirements. Different regions of the encapsulation pattern have different thicknesses optimized for their respective light-emitting elements, which prevents leakage current and reduces driving errors. This local optimization maintains manufacturing feasibility while significantly improving device reliability.
3Illumination intensity
If the display panel uses multiple light-emitting elements with different colors, then the display quality and color gamut are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent employs a universal partition wall structure and encapsulation approach that can accommodate multiple light-emitting elements of different colors (blue, green, red). The same basic manufacturing processes and structural elements are used across all color types, providing multi-functionality without increasing overall manufacturing complexity. This universal design enables high display quality with diverse color output while maintaining process simplicity.
Data Source
AI summary
A display panel includes a pixel-defining layer in which first and second light-emitting openings are defined, a partition wall in which first and second partition wall openings are defined, a first light-emitting element in the first partition wall opening, a second light-emitting element in the second partition wall opening, a first lower inorganic encapsulation pattern which covers the first light-emitting element, and a second lower inorganic encapsulation pattern which is spaced apart from the first lower inorganic encapsulation pattern and covers the second light-emitting element A thickness of the first lower inorganic encapsulation pattern is smaller than a thickness of the second lower inorganic encapsulation pattern.