OLED Array Substrate Self-Aligned Black Matrix via Light Exposure
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Solution Overview
Problem
Current OLED display panel manufacturing methods face challenges in achieving ultra-high resolution and flexibility due to the limitations of evaporation masks, which result in low light utilization and increased reflectance, making it difficult to reduce panel thickness while ensuring product flexibility.
Innovation Solution
A method of preparing an array substrate involving the formation of light emitting devices in an array on a base substrate, followed by the application and development of a black matrix using a positive photoresist containing black pigments, where the light emitting devices are activated to expose the black matrix material, allowing for self-alignment and improved light utilization, and potentially replacing the circular polarizer to reduce reflectance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If evaporation masks are used to form black matrix in OLED display panels, then manufacturing process is established, but alignment precision between black matrix and light emitting regions deteriorates resulting in low light utilization
Solution Approach 1:
The light emitting devices themselves are used to expose the photoresist material, creating the black matrix pattern. The devices activate the material that will define their own boundaries, achieving self-alignment without external masking tools. This self-service approach eliminates the alignment errors inherent in traditional evaporation mask methods.
Solution Approach 2:
Instead of using a mask to block light and define patterns (traditional approach), the invention inverts the logic by using the light emitting devices to actively expose the photoresist. The black matrix is formed by what the devices do not expose, creating patterns through absence rather than presence. This inversion fundamentally changes the alignment problem from a masking precision issue to a self-defined boundary issue.
2Object-affected harmful factors
If traditional black matrix formation methods are used, then manufacturing process is simple, but reflectance increases and panel thickness cannot be reduced
Solution Approach 1:
The invention extracts the circular polarizer from the OLED stack, replacing it with a black matrix formed directly in the substrate. This removal of the polarizer element reduces reflectance and allows for thinner panel design. The black matrix serves the dual function of defining pixel boundaries and reducing optical interference that previously required the polarizer.
Solution Approach 2:
The black matrix formed by the photoexposure method serves multiple functions simultaneously: it defines the pixel boundaries, reduces reflectance, and enables thinner panel construction. This multi-functional element replaces what previously required multiple separate components including the circular polarizer, simplifying the overall device structure while achieving the desired optical performance.
3Manufacturing precision
If evaporation masks are used for black matrix formation, then manufacturing process is established, but resolution deteriorates due to mask limitations
Solution Approach 1:
The invention replaces the mechanical evaporation mask system with a photochemical exposure system. Instead of physically masking areas during evaporation, the black matrix pattern is created through light exposure of photoresist material. This substitution enables much higher resolution since the exposure process can define features at the diffraction limit rather than being constrained by mask fabrication and alignment capabilities.
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 approach enhances light utilization efficiency and product resolution while maintaining panel flexibility by achieving precise alignment of the black matrix with light emitting regions, thereby reducing reflectance and enabling thinner OLED display panels.
Implementation Method 1
activating the plurality of light emitting devices to expose the black matrix material
Implementation Method 2
the light emitting devices are activated to expose the black matrix material
Data Source
AI summary
An array substrate, a method of preparing the array substrate, and a display panel are provided, the method of preparing the array substrate includes: providing a base substrate; forming a plurality of light emitting devices arranged in an array on the base substrate; covering the base substrate, on which the plurality of light emitting devices are formed, with a black matrix material; activating the plurality of light emitting devices to expose the black matrix material; and developing the exposed black matrix material to form a black matrix.