Flexible Display Panel Layout With Fewer Masks and Mixed TFTs
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Solution Overview
Problem
Existing display panel manufacturing processes face challenges in achieving high speed and reliability, particularly in flexible display designs, due to complex layer structures and the need for multiple masks in the manufacturing process, which increases costs and the risk of defects.
Innovation Solution
A display panel design featuring a base layer with a first and second area, where an inorganic layer overlaps both areas, and thin-film transistors with silicon and oxide semiconductor patterns are formed using a reduced number of masks, with insulation layers and an organic layer to enhance flexibility and simplify the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple masks are used in the manufacturing process to form complex layer structures, then the display panel can achieve high reliability and proper layer alignment, but the manufacturing complexity increases and the risk of defects increases
Solution Approach 1:
The patent combines multiple manufacturing steps into fewer process steps. Specifically, the pixel electrode and common electrode are formed in the same process step, and the emission control layer is integrated with the encapsulation structure. This merging reduces the number of masks required while maintaining layer alignment and product reliability.
Solution Approach 2:
The patent designs structures that serve multiple functions simultaneously. The encapsulation layer also serves as an emission control layer, and the electrode structure integrates both pixel and common electrodes. This multi-functionality reduces the number of separate manufacturing steps and masks needed.
2Manufacturing precision
If multiple masks are used in the manufacturing process, then precise layer alignment can be achieved, but the number of manufacturing steps and cost increase
Solution Approach 1:
The patent merges the formation of pixel electrodes and common electrodes into a single process step using a unified electrode layer. This approach maintains precise alignment through a single mask pattern while reducing the total number of manufacturing steps, thereby improving productivity without sacrificing alignment accuracy.
3Reliability
If complex layer structures are used to achieve high performance, then display quality improves, but flexibility and ease of manufacturing decrease
Solution Approach 1:
The patent implements multi-functional layers that achieve high display performance while simplifying manufacturing. The encapsulation layer simultaneously provides encapsulation and emission control functions, and the integrated electrode structure delivers both pixel and common electrode functions. This reduces structural complexity and ease of manufacture while maintaining display quality.
4Manufacturing precision
If more masks are used in the manufacturing process, then defect risk increases and cost increases, but layer formation completeness improves
Solution Approach 1:
The patent combines multiple layer formations into fewer process steps, reducing the total number of masks required. By forming the pixel electrode and common electrode in the same step and integrating the emission control layer with the encapsulation structure, the patent reduces opportunities for defects while maintaining complete layer formation.
Data Source
AI summary
A display panel includes a base layer including a first area and a second area. At least one inorganic layer disposed on the base layer overlaps the first area and the second area. The at least one inorganic layer comprises a lower opening. A first thin-film transistor is disposed on the at least one inorganic layer. The first thin-film transistor includes a silicon semiconductor pattern. A second thin-film transistor is disposed on the at least one inorganic layer. The second thin-film transistor includes an oxide semiconductor pattern. A plurality of insulation layers overlap the first area and the second area. An upper opening extends from the lower opening. A signal line is electrically connected to the second thin-film transistor. An organic layer is disposed in the lower opening and the upper opening. A light emitting element is disposed on the organic layer.