OLED Display Notch Formation via Deposition Mask and Dry Etching
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Solution Overview
Problem
Conventional methods for cutting notches in OLED display panels, such as laser cutting and cutter wheel cutting, often damage the encapsulation layer and organic light-emitting units, leading to display abnormalities and reduced production yield due to alignment difficulties and stress release at the notch edges.
Innovation Solution
A display panel motherboard with an array substrate featuring a notch reserved area where the organic light-emitting unit is not deposited, and an etch protection layer is applied on the encapsulation layer facing away from the array substrate, utilizing dry etching to form the notch, which reduces damage and improves precision and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser cutting or cutter wheel cutting is used to form notches in OLED display panels, then the notch can be created, but the encapsulation layer and organic light-emitting units are damaged, leading to display abnormalities and reduced production yield
Solution Approach 1:
The patent applies preliminary action by forming the notch reserved area during the organic light-emitting unit deposition process itself. The deposition mask is designed to automatically define the notch area, so the notch region is prepared in advance before any cutting or etching operations. This preliminary preparation ensures that subsequent processing steps can be performed with high precision without damaging the organic light-emitting units, as the deposition process already establishes the correct geometric boundaries.
Solution Approach 2:
The patent replaces mechanical cutting methods (laser cutting and cutter wheel cutting) with a deposition-based approach. Instead of using mechanical or thermal processes that damage the encapsulation layer, the invention uses vacuum deposition with a specially designed mask to form the notch reserved area. This substitution of mechanical systems with a deposition process eliminates the damage to the organic light-emitting units and encapsulation layer, thereby improving production yield while maintaining notch formation capability.
2Ease of manufacture
If laser cutting is used to form notches, then the notch can be created, but alignment difficulty arises during the cutting process, reducing precision
Solution Approach 1:
The patent applies preliminary action by establishing the notch reserved area boundaries during the organic light-emitting unit deposition process. The deposition mask is designed with precise geometric patterns that define the notch area, and this mask is aligned with the array substrate before deposition begins. By preparing the notch boundaries in advance through deposition rather than attempting to align cutting paths later, the invention eliminates alignment difficulties and achieves high precision notch formation.
3Ease of manufacture
If cutter wheel cutting is used to form notches, then the notch can be created, but the film layer and lines at the periphery of the mounting notch are damaged, causing display abnormality and sensing defect
Solution Approach 1:
The patent applies preliminary action by forming the notch reserved area during the organic light-emitting unit deposition process. The deposition mask automatically defines the notch boundaries, and the organic light-emitting units are deposited only in the areas that should remain. This preliminary preparation ensures that the periphery of the notch area is already protected and properly formed before any cutting or etching operations, eliminating film layer damage and display abnormalities at the notch edges.
Solution Approach 2:
The patent replaces mechanical cutter wheel cutting with a deposition-based approach. Instead of using mechanical forces that damage the film layers and lines at the notch periphery, the invention uses vacuum deposition to form the notch reserved area. This substitution eliminates the harmful mechanical effects on the organic light-emitting units and encapsulation layer, thereby preventing display abnormalities and sensing defects while maintaining notch formation capability.
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 minimizes damage to the encapsulation layer and organic light-emitting units during the cutting process, enhances notch alignment accuracy, and prevents photo-resistance failures, thereby improving the production yield and display quality of the OLED panels.
Implementation Method 1
by using the dry etching process for removing each film layer in the notch reserved area to forming a notch
Data Source
AI summary
The present disclosure relates to a display panel motherboard, a display panel, and a method of manufacturing the same, including a plurality of display substrates. The display substrate includes an organic light emitting unit; an array substrate, having at least one first area acting as a notch reserved area, and a second area different from the first area, the organic light emitting unit being formed on the array substrate and located on the second area; an encapsulation layer, formed on a side of the organic light emitting unit facing away from the array substrate and covering the notch reserved area; and an etch protection layer formed on a side of the encapsulation layer facing away from the array substrate.