Stretchable OLED Encapsulation via Undercut Structures
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Solution Overview
Problem
Current encapsulation technologies for stretchable OLED panels are limited by high pixel density, resulting in large gaps between subpixels and low pixel density, which hinders the stretchability and performance of the display panel.
Innovation Solution
The implementation of undercut structures in both island and chain regions of the display panel, with an encapsulation layer covering these structures, allows for a single encapsulation process that reduces gaps between subpixels and increases pixel density without the need for individual subpixel encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual encapsulation is performed for each subpixel using fine metal mask spreading process, then protection from water and oxygen is improved, but manufacturing complexity increases and pixel density is limited
Solution Approach 1:
The patent merges the encapsulation of multiple subpixels into a single unified encapsulation layer that covers the entire island region. Instead of performing individual encapsulation for each subpixel using separate fine metal mask processes, a single encapsulation layer is formed that simultaneously protects all subpixels, thereby reducing manufacturing complexity while maintaining protection reliability.
Solution Approach 2:
The encapsulation layer serves multiple functions simultaneously: it protects all subpixels from water and oxygen, defines the island region boundary, and enables higher pixel density through the belt-shaped chain region design. This multi-functional approach eliminates the need for separate individual encapsulation processes for each subpixel.
2Reliability
If individual encapsulation is performed for each subpixel, then protection from water and oxygen is improved, but gaps between subpixels increase and pixel density decreases
Solution Approach 1:
By combining the encapsulation of multiple subpixels under a single encapsulation layer, the patent eliminates the gaps that would exist between individually encapsulated subpixels. The unified encapsulation layer creates continuous coverage across all subpixels in the island region, maximizing the usable display area and increasing pixel density while maintaining protective functionality.
3Reliability
If fine metal mask spreading process is used for encapsulation, then individual subpixel protection is achieved, but the process is incapable of coping with high pixel distribution density
Solution Approach 1:
The patent merges the encapsulation approach from individual subpixel-level to region-level encapsulation. By forming a single encapsulation layer that covers the entire island region containing multiple subpixels, the process can accommodate high pixel distribution density without being constrained by the limitations of fine metal mask spreading processes required for individual subpixel encapsulation.
4Ease of manufacture
If blank frame region is maintained in packaging process, then manufacturing simplicity is preserved, but pixel density is reduced
Solution Approach 1:
The patent extracts and eliminates the blank frame region from the traditional packaging structure. By removing this non-functional space and extending the belt-shaped chain region to the edges of the substrate, the design maximizes the area available for subpixel distribution, thereby increasing pixel density without significantly complicating the manufacturing process.
Data Source
AI summary
The present application provides a display panel and a manufacturing method thereof. The display panel includes a plurality of display units. Each of the display units includes an island region and a chain region surrounding the island region. In at least one of the display units, the display panel includes an array substrate, a plurality of undercut structures, and an encapsulation layer. The undercut structures include a first undercut structure defined in the island region and a second undercut structure defined in the chain region.