OLED Display Panel Pixel Structure Without Fine Metal Masks
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Solution Overview
Problem
The manufacturing process and display performance of current OLED display products need improvement.
Innovation Solution
A display panel design featuring a substrate with a pixel defining layer and isolation structure, where the pixel defining portion and isolation structure include dimple structures, and the isolation structure has protrusions to facilitate the placement of light-emitting devices, allowing for separate evaporation of different colored devices without the need for fine metal masks, enhancing adhesion and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fine metal masks are used for separate evaporation of different colored light-emitting devices, then manufacturing precision is improved, but device complexity and production cost increase
Solution Approach 1:
The patent extracts the positioning function from the mask system by creating protrusion structures directly on the substrate. These protrusions serve as physical guides that determine the placement positions of light-emitting devices, eliminating the need for complex fine metal masks while maintaining precise positioning.
Solution Approach 2:
The protrusion structures act as intermediary elements between the substrate and the light-emitting devices. They provide a mechanical interface that ensures accurate placement without requiring complex masking systems, thus resolving the contradiction between precision and complexity.
2Ease of manufacture
If conventional flat structures are used for pixel defining and isolation, then manufacturing process is simplified, but adhesion between film layers deteriorates
Solution Approach 1:
The patent introduces curved surface structures (protrusions and dimples) instead of flat surfaces. The protrusions on the substrate and corresponding dimples in the pixel defining layer create interlocking geometric features that significantly enhance adhesion between layers while maintaining manufacturing feasibility through standard deposition processes.
Solution Approach 2:
The patent applies local geometric modifications (protrusions and dimples) at specific critical locations rather than changing the entire structure. This localized approach enhances adhesion where needed while keeping the overall manufacturing process simple and avoiding unnecessary complexity elsewhere in the device.
3Ease of manufacture
If electrical connections are made on flat surfaces, then manufacturing is easier, but electrical connection quality deteriorates
Solution Approach 1:
The patent uses protrusion and dimple structures to create increased surface area and mechanical interlocking for electrical connections. The curved geometries provide better contact interfaces that improve electrical connection reliability while remaining compatible with standard manufacturing processes.
Data Source
AI summary
A display panel, a manufacturing method of the display panel, and a display device. The display panel includes a substrate; a pixel defining layer disposed on a side of the substrate and including a pixel defining portion and a plurality of pixel openings formed by enclosing the pixel defining portion; an isolation structure disposed on the side of the substrate, where a plurality of isolation openings are disposed on the isolation structure, and the plurality of isolation openings communicate with the plurality of pixel openings; a plurality of light-emitting devices at least partially located within the plurality of pixel openings, where the pixel defining portion exposed from at least part of the plurality of isolation openings has a dimple structure disposed on a side facing away from the substrate.