OLED Pixel Defining Layer Spacer Integration
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Solution Overview
Problem
The existing manufacturing process for OLED display substrates combining LTPS backboards with FMM Masks is complex due to the separate processes for forming spacers and pixel defining layers, which complicates the production and requires additional steps.
Innovation Solution
A pixel defining layer made of polyimide resin is used to both define pixels and support the gap between the upper and lower substrates, thereby eliminating the need for a separate spacer and simplifying the manufacturing process by combining the functions of both layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate processes are used for forming spacers and pixel defining layers, then each layer can be optimized independently, but the manufacturing process becomes complex and requires additional steps
Solution Approach 1:
The patent combines the spacer and pixel defining layer into a single integrated structure. The pixel defining layer is formed to extend from the pixel electrode to the common electrode, simultaneously serving as both the pixel boundary definition and the spacer for maintaining substrate gap, thereby eliminating the need for separate spacer formation processes
Solution Approach 2:
The pixel defining layer is designed to perform multiple functions: it defines the pixel boundaries, isolates adjacent pixels electrically, and acts as a spacer to maintain the gap between upper and lower substrates. This multi-functional design simplifies the overall manufacturing process while maintaining optimization benefits
2Reliability
If a separate spacer is used to support the gap between substrates, then the gap support function is dedicated and reliable, but the manufacturing process requires additional steps and materials
Solution Approach 1:
The spacer function is merged into the pixel defining layer. The pixel defining layer extends vertically to contact both the upper and lower substrates, providing mechanical support for the gap between substrates while being formed in the same process as the pixel defining structure, thereby eliminating separate spacer materials and steps
3Manufacturing precision
If multiple layers are formed separately, then each layer can be precisely controlled, but the production efficiency decreases and time is increased
Solution Approach 1:
The formation of the pixel defining layer and spacer is combined into a single deposition and patterning process. The pixel defining layer is formed to extend through the entire gap distance, simultaneously achieving precise layer control for pixel definition and gap support while reducing the number of manufacturing steps to improve productivity
Data Source
AI summary
A display substrate and a fabrication method thereof and a display device. The display substrate includes: a plurality of pixels disposed on a lower substrate; and a pixel defining layer disposed between adjacent pixels of the plurality of pixels, the pixel defining layer contacting with an upper substrate of the plurality of pixels, the pixel defining layer configured for defining each pixel and supporting a gap between the upper substrate and the lower substrate.