Pixel Define Layer With Dual Opening Structure For Droplet Confinement
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Solution Overview
Problem
Existing display panels, such as OLED and LCD, face defects like cross-color and Mura due to droplets from printing methods deviating and flowing into adjacent pixel regions, which is costly to address with current methods that require high investment and apparatus upgrades for mass production.
Innovation Solution
A display panel with a pixel define layer comprising a photosensitive resin layer and a transparent define layer, where the transparent define layer has openings smaller than the photosensitive resin layer, forming a fill region with a wide lower and narrow upper portion, allowing for even and smooth filling of liquid materials without the need for surface treatments or additional apparatus investment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a printing method is used to form light-emitting material or color filter material, then the material can be deposited on the substrate, but the droplet may deviate from the target pixel region and flow into adjacent pixel regions causing defects
Solution Approach 1:
The pixel define layer is divided into two distinct layers: a photosensitive resin layer and a transparent define layer. Each layer serves a specific function - the photosensitive resin layer defines the upper boundary of the fill region through photolithography, while the transparent define layer defines the lower boundary and provides hydrophobic/hydrophilic properties to control droplet flow. This segmentation allows precise control over droplet placement without requiring high positioning accuracy from the printing process itself.
Solution Approach 2:
The transparent define layer is made of a material with specific hydrophobic or hydrophilic properties that differ from the photosensitive resin layer. This creates local quality differences in surface energy across the pixel define layer, causing droplets to be attracted to and confined within specific regions (the fill region) regardless of their initial deposition position. The local quality change in surface properties ensures that even deviated droplets will flow into the correct pixel region.
2Manufacturing precision
If surface treatment (fluorination or ultraviolet irradiation) is applied to change the wetting property of the pixel define layer, then droplet flow can be controlled, but the investment in apparatus and manufacturing cost increases
Solution Approach 1:
Instead of applying additional surface treatments like fluorination or ultraviolet irradiation that require specialized apparatus, the patent changes the fundamental parameter of the pixel define layer by using a transparent define layer made of materials with inherently different hydrophobic/hydrophilic properties. This material parameter change achieves droplet flow control through the natural surface properties of the transparent define layer material, eliminating the need for complex surface treatment equipment while maintaining precise droplet confinement.
3Manufacturing precision
If the opening size of the pixel define layer is increased to ensure even coverage, then the material can cover the pixel region smoothly, but the droplet may flow into adjacent pixel regions
Solution Approach 1:
The patent solves the coverage vs. confinement contradiction by adding a vertical dimension with two stacked layers (photosensitive resin layer and transparent define layer) instead of relying solely on horizontal opening size control. The photosensitive resin layer provides a large upper opening for even material distribution, while the transparent define layer provides a smaller lower opening that acts as a confinement barrier. This dimensional approach allows both smooth coverage and prevention of cross-pixel flow simultaneously.
Solution Approach 2:
The transparent define layer acts as an intermediary structure between the substrate and the photosensitive resin layer. It mediates the conflict between needing a large opening for even coverage and needing a small opening to prevent droplet overflow. The transparent define layer's hydrophobic/hydrophilic properties serve as a mediator that guides droplet flow into the correct regions while the photosensitive resin layer's larger opening ensures uniform material distribution.
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
This solution prevents droplets from flowing into adjacent pixel regions, reduces manufacturing costs, and enables mass production by ensuring accurate and defect-free display panel formation, improving display quality and simplifying the manufacturing process.
Implementation Method 1
The transparent define layer is made of a hydrophobic material
Implementation Method 2
The transparent define layer is made of a hydrophilic material
Data Source
AI summary
Embodiments of the invention provide a display panel with a pixel define layer, a manufacturing method of a pixel define layer of a display panel, and a display device. The display panel with the pixel define layer comprises: a substrate and the pixel define layer disposed on the substrate. The pixel define layer includes a photosensitive resin layer and a transparent define layer sequentially disposed on the substrate. The photosensitive resin layer has an opening in a region corresponding to each pixel region of the display panel, the transparent define layer has an opening in the region corresponding to each pixel region of the display panel, and the opening of the transparent define layer is smaller than the opening of the photosensitive resin layer so as to form a fill region with a wide lower portion and a narrow upper portion.