Organic Light-Emitting Panel Indentation Bank Taper
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Solution Overview
Problem
The existing organic light-emitting panels fabricated using the inkjet method face issues that affect the yield rate and quality, necessitating improvements in the fabrication process.
Innovation Solution
The proposed organic light-emitting panel design includes a substrate with a planarization layer featuring an indentation, a reflective layer formed along the sidewall of the indentation, and a bank layer with taper surfaces. The bank layer's periphery taper surface is more gradual than the display region taper surface, ensuring continuity of subsequent film layers and improving the yield rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the inkjet method is used to fabricate the organic light-emitting material on the substrate, then the fabrication efficiency is improved, but the yield rate and quality of the organic light-emitting panel deteriorate
Solution Approach 1:
The patent applies preliminary action by forming an indentation structure in the planarization layer before depositing the reflective layer. This pre-prepared geometric feature ensures that the reflective layer automatically forms a tapered structure along the sidewalls of the indentation, which subsequently prevents film disconnection issues during inkjet fabrication of the organic light-emitting material. The preliminary geometric preparation resolves the contradiction by enabling both efficient inkjet fabrication and high yield rate.
Solution Approach 2:
The patent introduces an intermediary structure (the indentation with reflective layer forming a tapered surface) between the substrate and the organic light-emitting material. This intermediary tapered structure acts as a transition zone that accommodates the inkjet deposition process, preventing film disconnection while maintaining fabrication efficiency. The intermediary structure mediates between the fabrication process requirements and the final product quality.
2Manufacturing precision
If a steep taper surface is formed on the bank layer, then the structural definition is improved, but the continuity of subsequent film layers deteriorates due to disconnection
Solution Approach 1:
The patent applies local quality by creating different taper angles in different regions. The bank layer has a steep taper surface in the display region for good structural definition, while the periphery region has a gentle taper surface (with inclination angle of 5-15 degrees) that ensures film layer continuity. This localized differentiation of taper angles resolves the contradiction between structural definition and film continuity.
Solution Approach 2:
The patent resolves the contradiction by transitioning from a two-dimensional flat surface to a three-dimensional tapered structure with varying angles. The indentation depth (1-6 μm) and the differential taper angles create a multi-level surface topology that simultaneously provides structural definition where needed and gentle slopes for film continuity where required.
3Stability of the object's composition
If the periphery taper surface is made more gradual, then the continuity of film layers is improved, but the angle of inclination increases beyond conventional ranges
Solution Approach 1:
The patent applies parameter changes by modifying the inclination angle parameter of the periphery taper surface to be within 5-15 degrees, which is gentler than conventional taper surfaces. This parameter adjustment ensures that subsequent film layers maintain continuity without disconnection. The gentle angle is achieved through the specific geometry of the indentation structure and the reflective layer deposition process.
Data Source
AI summary
An organic light-emitting panel, including a substrate, a planarization layer, a reflective layer and a bank layer, is provided. The substrate has a display region and a periphery region beside the display region. The planarization layer is disposed on the substrate and has an indentation. The reflective layer is disposed on the planarization layer. The reflective layer is formed along a sidewall of the indentation. The bank layer is disposed on the planarization layer, covers the indentation, and has a periphery taper surface. The indentation is adjacent to the periphery taper surface and is closer to the display region than the periphery taper surface. A fabrication method of the above organic light-emitting panel is also provided.