Display Panel Trace Layout Using Grooves and Protrusions
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Solution Overview
Problem
Existing display panels face challenges in efficiently arranging a large number of traces in a limited space, particularly due to the constraints of trace spacing and layout complexity, which affects the screen-to-body ratio and functional requirements.
Innovation Solution
The display panel design incorporates a first insulating layer with alternating grooves and protrusions, where first and second traces are arranged on the top surfaces and bottom surfaces of the protrusions and grooves, respectively, with specific angles and depths to minimize trace spacing and allow for more traces to be packed into a given area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If organic light-emitting materials are used to achieve full-color display, then display quality is improved, but material degradation and burning out occur reducing reliability
Solution Approach 1:
The organic light-emitting layer is divided into multiple sub-layers including hole injection layer, hole transport layer, emission layer, electron transport layer, and electron injection layer. Each sub-layer is composed of specific organic materials optimized for its function, allowing precise control of charge injection and transport to improve efficiency and reduce material degradation.
Solution Approach 2:
Buffer layers are introduced as intermediary structures between the electrode and organic light-emitting layers. These buffer layers serve as mediators to optimize charge injection, protect the organic materials from direct contact with electrodes, and reduce degradation, thereby improving both display quality and reliability simultaneously.
2Productivity
If conventional manufacturing processes are used, then existing production capabilities are maintained, but manufacturing efficiency and productivity are low
Solution Approach 1:
Multiple manufacturing steps are merged into a single vacuum deposition process. The patent describes a integrated fabrication method where substrate preparation, buffer layer deposition, organic layer deposition, and electrode formation are combined into one continuous vacuum deposition process, significantly improving productivity while maintaining control over process complexity.
3Illumination intensity
If simple device structures are used, then manufacturing is easier, but display performance and quality are insufficient
Solution Approach 1:
Different regions of the device structure are optimized with specific materials and properties tailored to local requirements. Each organic layer is composed of materials with specific HOMO/LUMO energy levels, mobility characteristics, and thickness optimized for its particular function in the overall device, achieving high display performance through localized optimization rather than uniform structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enables a significant reduction in horizontal trace spacing, allowing for a higher density of traces and light-emitting devices, thereby enhancing the screen-to-body ratio and supporting larger under-screen functional regions.
Implementation Method 1
a vacuum deposition apparatus for depositing organic materials
Implementation Method 2
a plasma treatment unit for treating a substrate to be processed
Data Source
Figure 1~2(D)
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AI summary
The present disclosure provides a display panel, a manufacturing method thereof and a display apparatus. The display panel includes: a base substrate; a first insulating layer on a side of the base substrate; the first insulating layer includes a plurality of grooves and a plurality of protrusions on a side of the first insulating layer away from the base substrate and alternately arranged in sequence; and traces on the side of the first insulating layer away from the base substrate, the traces include first traces and second traces, each first trace is on a side of the top surface of the corresponding protrusion of the first insulating layer away from the base substrate, and each second trace is on the bottom surface of the corresponding groove.