OLED Display Panel Hole Planarization via Organic Layer
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Solution Overview
Problem
The existing manufacturing process of OLED display panels requires multiple coating processes to planarize the surface due to a significant height difference between the hole forming area and the display area, increasing production time and cost.
Innovation Solution
A display panel design that includes an organic material layer in the hole forming area, composed of stacked sub-layers made of the same materials as the pixel defining and planarization layers, to reduce the height difference to less than 4 um, allowing for a single coating process to achieve planarization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If the display film layer is removed in the hole forming area to facilitate cutting, then the screen-to-body ratio is increased, but a large height difference (8-10 um) is created between the hole forming area and display area
Solution Approach 1:
The organic material layer is formed in the hole forming area during the manufacturing process before the touch function layer is applied. This preliminary action fills the height difference created by removing the display film layer, ensuring that the surface is sufficiently planarized (height difference reduced to less than 4 um) to allow for a single coating process of the planarization material, thereby eliminating the need for multiple coating steps while maintaining the high screen-to-body ratio achieved by hole formation.
2Manufacturing precision
If multiple coating processes are performed to planarize the surface, then the height difference is reduced, but the production time and manufacturing cost increase
Solution Approach 1:
The organic material layer is formed in advance during the OLED manufacturing process, creating a preliminary planarization structure. This preliminary action reduces the height difference to less than 4 um, which is sufficient for the subsequent single coating process of the planarization material to achieve the required surface flatness. By performing this planarization preparation in advance, the need for multiple coating processes is eliminated, thereby reducing production time and manufacturing cost while maintaining the required surface planarization quality.
3Manufacturing precision
If multiple coating processes are performed to achieve planarization, then the surface flatness is improved, but the manufacturing complexity increases
Solution Approach 1:
The organic material layer is formed during the OLED manufacturing process as a preliminary planarization structure. This preliminary action creates a surface with height difference less than 4 um, which allows the subsequent planarization process to be completed with a single coating step instead of multiple coating processes. By integrating the planarization preparation into the existing manufacturing flow, the overall manufacturing complexity is reduced while achieving the required surface flatness for the touch function layer.
Data Source
AI summary
A display panel, a manufacturing method thereof and a display device are provided. The display panel includes a display area and a hole forming area, where the display area surrounds the hole forming area, and an organic material layer is provided in the hole forming area so that a height difference between the hole forming area and the display area is less than a threshold value of 4 um.