Flexible Display Panel Adhesion via Through Hole Design
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Solution Overview
Problem
The manufacturing process of film layers in display panels results in weakened adhesion between layers, leading to peeling when the panel is bent, thereby shortening its service life.
Innovation Solution
A display panel design featuring a flexible substrate with an array layer, pixel definition layer, insulating layer with specific through holes, light-emitting layer, additional layer, and inorganic layers, where the second through holes are designed with top diameters less than bottom diameters and second parts of the additional layer are not connected, enhancing adhesion between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional film layer manufacturing process is used, then manufacturing simplicity is maintained, but adhesion between film layers deteriorates leading to peeling during bending
Solution Approach 1:
The patent divides the through holes into two distinct types: first through holes filled with light-emitting layer material, and second through holes containing additional layer material. This segmentation allows different regions to serve different functions - the first through holes provide light emission while the second through holes enhance adhesion between the array layer and encapsulation layers, preventing peeling during bending without compromising manufacturing feasibility
Solution Approach 2:
The patent applies different materials and structures to different locations within the display panel. Specifically, the additional layer material is selectively placed in second through holes at specific positions where adhesion enhancement is most needed, while light-emitting layer material is placed in first through holes. This localized approach optimizes adhesion strength at critical interfaces without unnecessarily complicating the entire structure
2Adaptability or versatility
If film layers are bent after manufacturing, then flexibility is achieved, but adhesion between layers deteriorates causing peeling
Solution Approach 1:
The patent performs preliminary adhesion enhancement by filling second through holes with additional layer material before the bending process occurs. This additional layer material creates strong bonding between the array layer and encapsulation layers in advance, so when bending occurs later, the pre-established adhesion prevents peeling. The through holes are prepared and filled during manufacturing, ensuring adhesion strength is established before flexibility is utilized
Solution Approach 2:
The patent uses composite material structures where the additional layer material is combined with the array layer and encapsulation layers through the second through holes. This creates a multi-material composite structure that maintains strong interlayer adhesion during bending, while the overall device retains flexibility. The composite structure of different materials working together prevents peeling under mechanical stress
Data Source
AI summary
The present disclosure provides a display panel and a manufacturing method thereof, which include a flexible substrate, an array layer, a pixel definition layer, an insulating layer, a light-emitting layer, an additional layer, and a first inorganic layer. The array layer, the pixel definition layer, and the insulating layer are sequentially disposed on the flexible substrate, the insulating layer includes first through holes and second through holes, the light-emitting layer is filled in the first through holes, and the additional layer is disposed on the pixel definition layer, in the second through holes, and on the insulating layer and the light-emitting layer. The first inorganic layer is disposed on the array layer and the additional layer.