OLED Display Panel Dual-Layer Flat Structure for Planarization and Gas Barrier
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Solution Overview
Problem
Existing OLED display panels face challenges in achieving both good planarization and minimizing gas impurity release, leading to non-uniform light emission and reduced panel quality due to the limitations of single flat layers with either low or high viscosity materials.
Innovation Solution
A dual-layer flat structure is introduced, with a first flat layer of low viscosity (less than 4 centipoise) and a second flat layer of higher viscosity (greater than or equal to 4 centipoise), made from acrylic and polyimide materials respectively, to enhance planarization and reduce gas impurity transmission, while the OLED light emitting layer is formed using an inkjet printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flat layer is made of material with lower viscosity to improve planarization effect, then the flattening effect is better and film thickness is more uniform, but gas impurities are released more and affect OLED lifetime
Solution Approach 1:
The flat layer is divided into two separate layers: a first flat layer with lower viscosity material for planarization, and a second flat layer with higher viscosity material to block gas impurities. This segmentation allows each layer to perform its specific function independently, resolving the contradiction between planarization quality and gas impurity release.
Solution Approach 2:
The flat layer uses a composite structure combining two different materials with different viscosity characteristics. The lower viscosity material provides good planarization while the higher viscosity material provides gas barrier properties, achieving both objectives simultaneously through material composition design.
2Reliability
If a flat layer is made of material with higher viscosity to reduce gas impurity release, then gas impurities are reduced, but the flat layer is not very flat causing non-uniform light emission
Solution Approach 1:
By dividing the flat layer into two functional layers, the patent allows the first layer to specialize in planarization (using lower viscosity material) while the second layer specializes in gas barrier function (using higher viscosity material), eliminating the need to compromise either function in a single-layer design.
Solution Approach 2:
Different regions of the flat layer structure are assigned different material properties: the lower layer uses low viscosity material optimized for planarization, while the upper layer uses high viscosity material optimized for gas barrier performance. Each local region performs its specific function optimally.
Data Source
AI summary
The present disclosure relates to an OLED display panel. The OLED display panel includes a TFT array substrate, and a flat layer on the TFT array substrate. The flat layer includes a first flat layer and a second flat layer on the first flat layer. A viscosity of the first flat layer is less than a viscosity of the second flat layer. In addition, the present disclosure also relates to a manufacturing method of the OLED display panel to enhance the performance of the OLED display panel.