Flattening Device Protrusions for Display Substrate Surface
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Solution Overview
Problem
During the manufacturing of display substrates, the surface energy difference between ink droplets and the pixel definition layer, along with the trapezoid structure of the pixel definition layer, leads to convex or concave surfaces of dried pixel material, causing defects like electric leakage and uneven light emission, which degrade display performance.
Innovation Solution
A method involving a flattening device with protrusions is used to flatten uncured sub-pixel material within sub-pixel regions defined by a pixel definition layer, ensuring a flat surface through repeated rolling and alignment, with an anti-corrosion layer on the protrusions to prevent corrosion and using lyophobic materials to prevent adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If inkjet printing is used to form sub-pixel material in sub-pixel regions, then material deposition efficiency is improved, but the surface of the dried pixel material becomes convex or concave due to surface energy difference and trapezoid structure of pixel definition layer
Solution Approach 1:
The flattening device is introduced to perform preliminary flattening action on the uncured sub-pixel material before curing. The protrusions on the flattening device press into the uncured material to eliminate convexities and fill concavities, achieving a flat surface that prevents subsequent defects like electric leakage and uneven light emission
2Manufacturing precision
If a flattening device with protrusions is used to flatten uncured sub-pixel material, then surface flatness is improved, but the protrusions may be corroded by the organic light-emitting material
Solution Approach 1:
An anti-corrosion layer is introduced as an intermediary between the protrusions and the organic light-emitting material. This protective layer prevents direct contact and chemical reaction between the protrusions and the material, eliminating corrosion while maintaining the flattening function
Solution Approach 2:
The flattening device employs composite material construction with an anti-corrosion layer coating on the protrusions. This composite structure combines the mechanical flattening capability of the protrusion material with the chemical resistance of the anti-corrosion layer
3Manufacturing precision
If the protrusions directly contact the uncured sub-pixel material during flattening, then flattening effect is achieved, but the protrusions adhere to the material due to surface energy differences
Solution Approach 1:
The anti-corrosion layer serves as an intermediary that also prevents adhesion between the protrusions and the uncured sub-pixel material. By eliminating direct contact, it prevents the harmful adhesion effect while preserving the mechanical pressure transmission needed for flattening
Solution Approach 2:
The surface properties of the protrusions are modified by applying the anti-corrosion layer, which changes the surface energy characteristics to reduce adhesion to the organic light-emitting material while maintaining sufficient contact pressure for effective flattening
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
The method achieves flat sub-pixel surfaces, improving display performance by preventing defects such as electric leakage and ensuring uniform light emission.
Implementation Method 1
The flattening device comprises an anti-corrosion layer on the protrusion surface of the protrusion
Implementation Method 2
a material of the protrusion comprises a lyophobic material for the sub-pixel material
Data Source
AI summary
A flattening device, a display substrate and a method for manufacturing the display substrate are provided. The method includes providing a base substrate, forming a pixel definition layer on the base substrate and forming an uncured sub-pixel material in a plurality of sub-pixel regions defined by the pixel definition layer, and flattening the uncured sub-pixel material by a flattening device. The flattening device includes a main body and a plurality of protrusions on a surface of the main body. A size of a protrusion surface of each protrusion facing away from the main body is not greater than that of each sub-pixel region. The sub-pixels are flattened by using the flattening device, so a sub-pixel material layer with a flat surface may be obtained, which improves the structure of the sub-pixels and improves the display performance of the display substrate.