Flexible Display Electrode Segmentation via Partition Walls
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Solution Overview
Problem
The production of flexible OLED display panels faces challenges due to the need for expensive fine metal masks during electrode patterning, which increases production costs and reduces efficiency, and the lack of sufficient stress tolerance and ductility in continuous first electrodes, leading to damage during bending or stretching.
Innovation Solution
A flexible display panel design featuring pixel island areas with partition walls that continuously decrease or intermittently change in width, allowing for patterned electrodes without the use of fine metal masks, thereby reducing production costs and improving efficiency, and enhancing stress tolerance through the formation of patterned islands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fine metal masks are used during electrode patterning, then manufacturing precision is improved, but production cost increases and productivity decreases
Solution Approach 1:
The first electrode is divided into multiple isolated patterned islands corresponding to different pixel island areas, with partition walls between them. This segmentation eliminates the need for fine metal masks during evaporation deposition or sputtering, as the partition walls automatically define the electrode patterns, thereby improving productivity while maintaining manufacturing precision
Solution Approach 2:
Partition walls are introduced as intermediary structures between pixel island areas. These partition walls serve as physical barriers that prevent electrode material from bridging adjacent pixels during deposition, replacing the function of fine metal masks without their associated cost and complexity issues
2Manufacturing precision
If fine metal masks are used during electrode patterning, then manufacturing precision is improved, but production cost increases
Solution Approach 1:
The first electrode is divided into multiple isolated patterned islands corresponding to different pixel island areas, with partition walls between them. This segmentation eliminates the need for fine metal masks during evaporation deposition or sputtering, as the partition walls automatically define the electrode patterns, thereby improving productivity while maintaining manufacturing precision
Solution Approach 2:
The partition walls are formed as permanent structural elements during the pixel definition layer formation process, serving as disposable pattern-defining structures that eliminate the need for expensive, reusable fine metal masks. This one-time formation approach reduces overall manufacturing cost
3Reliability
If continuous first electrodes are used, then electrical conductivity is improved, but stress tolerance decreases leading to damage during bending or stretching
Solution Approach 1:
The first electrode is segmented into multiple isolated patterned islands rather than a continuous structure. Each island corresponds to a pixel island area and is electrically connected through the substrate, providing both stress tolerance during bending/stretching and sufficient electrical conductivity for device operation
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 solution eliminates the need for fine metal masks, reduces production costs, and improves production efficiency while increasing the stress tolerance and ductility of the first electrode, enabling effective bending and stretching of the display panel without damage.
Implementation Method 1
during the process of forming the first electrode using evaporation deposition or sputtering
Implementation Method 2
during the process of forming the first electrode using evaporation deposition or sputtering
Data Source
AI summary
A flexible display panel includes a pixel definition layer, a partition wall, and a first electrode. The partition wall is disposed on the pixel definition layer and located within the pixel island area. Each pixel island area includes at least one partition wall. The first electrode is disposed on the pixel definition layer. A width of the partition wall continuously decreases or intermittently changes from top to bottom along a thickness direction of the partition wall. The first electrode includes a plurality of patterned islands that are in one-to-one correspondence with the plurality of pixel island areas and are spaced apart by the partition walls.