OLED Display Panel Interval Layer Peeling Process
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Solution Overview
Problem
The peeling process in OLED display manufacturing is lengthy and damages the light-emitting material, and it can cause color crossing between subpixels due to prolonged contact and large peeling areas.
Innovation Solution
A display panel design with a substrate, pixel defining layer, light-emitting layer, and an interval layer that is disconnected from the adjacent light-emitting layer, using a peeling process to form the light-emitting layer and interval layer, reducing the peeling area and time, and preventing color crossing by maintaining a gap between them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a peeling process is used to form the light-emitting layer in the prior art, then the light-emitting layer can be patterned with high resolution and high accuracy, but the peeling time is long and the contact time between peeling solution and EL is prolonged which affects working stability
Solution Approach 1:
The patent introduces an interval layer that divides the continuous light-emitting layer into separate segments corresponding to different subpixels. This segmentation allows the peeling process to be performed more efficiently by reducing the total peeling area and time, while maintaining the high precision patterning capability for each individual subpixel region.
Solution Approach 2:
The interval layer is formed in advance before the final light-emitting layer patterning step. By pre-establishing the interval structures that define the boundaries between subpixels, the subsequent peeling process becomes more efficient and requires less time, while still achieving the required high precision patterning.
2Manufacturing precision
If a peeling process is used to achieve patterning of a light-emitting film layer, then the light-emitting layer can be precisely patterned, but the area of the non-target region is large and the time for peeling is long
Solution Approach 1:
By introducing the interval layer that segments the light-emitting layer into distinct subpixel regions, the patent reduces the total area requiring peeling treatment. This segmentation strategy maintains precise patterning control for each subpixel while significantly improving manufacturing efficiency by reducing overall process time.
3Ease of manufacture
If the peeling solution contacts the light-emitting material for a prolonged period, then the light-emitting layer can be fully peeled, but the working stability of the OLED is affected
Solution Approach 1:
The interval layer creates discrete regions that limit the spread and contact area of the peeling solution. This segmentation ensures complete peeling of the light-emitting layer where needed while reducing overall solution contact time, thereby maintaining OLED working stability.
4Device complexity
If the light-emitting layer is formed without an interval layer, then the manufacturing process is simpler, but color crossing between different subpixels occurs
Solution Approach 1:
The interval layer acts as a physical barrier that segments and isolates adjacent subpixel regions. This segmentation prevents color crossing between subpixels by maintaining clear boundaries, while the added structural complexity remains manageable and justified by the significant improvement in display quality.
5Stability of the object's composition
If the interval layer is connected to the adjacent light-emitting layer, then the structure is more continuous, but color crossing between subpixels occurs
Solution Approach 1:
The interval layer is deliberately designed to be disconnected from the adjacent light-emitting layer, creating intentional gaps that segment the structure. This segmentation strategy prioritizes color isolation precision over structural continuity, preventing color crossing between subpixels while maintaining adequate structural integrity for device function.
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
The solution shortens peeling time, reduces material damage, and prevents color crossing between subpixels, improving the display effect by minimizing contact between light-emitting layers and interval layers.
Implementation Method 1
a photo pattern typesetting technology, with its characteristics of high resolution and high accuracy, has very obvious advantages in the manufacturing process of products with a high pixel density (PPI) and a high aperture ratio. The photo pattern for typesetting OLED pixels relies on a peeling technology to achieve patterning of a light-emitting film layer of each subpixel by peeling a film layer in a non-target region.
Data Source
AI summary
The display panel includes: a substrate; a pixel defining layer, arranged on the substrate, and comprising a plurality of opening regions arranged in an array; a light-emitting layer, configured to cover at least the plurality of opening regions; and an interval layer, arranged on the pixel defining layer and disconnected from an adjacent light-emitting layer.