Flexible display panel, manufacturing method thereof, display device and mask
Technical Field
The invention relates to the technical field of display, in particular to a flexible display panel, a manufacturing method of the flexible display panel, a display device and a mask.
Background
Flexible display devices are receiving increasing attention due to their bendable nature. And an OLED (Organic Light-Emitting Diode) is a main component applied in the flexible display device. In the OLED flexible display device, the cathode layer is coated with a film on the whole surface, and in the bending process, the stress cannot be effectively released, so that the cathode layer is easy to deform, or the cathode layer is peeled from the upper film layer and the lower film layer, and the performance of the flexible display device is influenced.
Disclosure of Invention
In order to solve the above problems, embodiments of the present invention disclose a flexible display panel, a display device, and a mask.
A flexible display panel includes a cathode layer including a first hollowed-out area.
Further, the cathode layer comprises a plurality of cathodes which are arranged at intervals and electrically connected with each other, and the first hollow-out area is formed between every two adjacent cathodes.
Furthermore, the cathode layer further comprises a plurality of first connecting bridges, and the two adjacent cathodes are electrically conducted through at least one first connecting bridge.
Further, the cathode and the first connection bridge are formed simultaneously by using a fine mask.
Further, the flexible display panel further comprises a plurality of pixel units, the cathode is arranged corresponding to one of the pixel units, and the pixel unit comprises at least one pixel area.
Further, the pixel region includes a light emitting region and a non-light emitting region connected to the light emitting region.
Further, the long side direction of the cathode is parallel to the bending axis of the flexible display device.
Furthermore, the flexible display panel further comprises an organic light emitting layer and an encapsulation layer which are stacked with the cathode layer, the cathode layer is arranged between the encapsulation layer and the organic light emitting layer, and the encapsulation layer fills the first hollow area.
Furthermore, the flexible display panel further comprises a substrate, a thin film transistor, an anode layer and a pixel definition layer, wherein the thin film transistor, the anode layer, the pixel definition layer, the organic light emitting layer and the cathode layer are sequentially stacked on the substrate, and the thin film transistor is adjacent to the substrate.
A display device comprising a flexible display panel as described above.
A mask is used for manufacturing a cathode layer of a flexible display panel, a non-hollowed-out area is formed on the mask, and the non-hollowed-out area is used for forming a first hollowed-out area of the cathode layer.
Furthermore, the mask plate comprises a plurality of second hollowed-out areas arranged at intervals, the non-hollowed-out area is formed between every two adjacent second hollowed-out areas, and the second hollowed-out areas are used for forming a cathode of the cathode layer.
Furthermore, the mask plate further comprises a plurality of third hollow-out areas, two adjacent second hollow-out areas are communicated through at least one third hollow-out area, and the third hollow-out areas are used for forming a first connecting bridge of the cathode layer.
A manufacturing method of a flexible display panel comprises the step of forming a cathode layer of the flexible display panel by using a mask, wherein the mask comprises a non-hollowed-out area, and the cathode layer comprises a first hollowed-out area formed corresponding to the non-hollowed-out area.
Further, the "forming a cathode layer of a flexible display panel using a mask" further includes: the mask plate further comprises a plurality of second hollowed-out areas arranged at intervals, the non-hollowed-out area is formed between every two adjacent second hollowed-out areas, and the cathode layer further comprises a cathode formed corresponding to the second hollowed-out areas.
Furthermore, the mask plate further comprises a plurality of third hollow-out areas, two adjacent second hollow-out areas are communicated through at least one third hollow-out area, the cathode layer further comprises a first connecting bridge formed corresponding to the third hollow-out areas, and two adjacent cathodes are electrically connected through at least one first connecting bridge.
Further, the "forming a cathode layer of a flexible display panel using a mask" further includes: the second hollow-out region is arranged corresponding to one pixel unit of the flexible display panel, the pixel unit comprises at least one pixel region, and the cathode is arranged corresponding to one pixel unit.
Further, after the step of forming the cathode layer of the flexible display panel by using the mask, the manufacturing method further comprises the steps of: and forming an encapsulation layer on the cathode layer, wherein the encapsulation layer fills the first hollow area.
A mask is used for manufacturing a cathode layer of a flexible display panel, a light transmitting area is formed on the mask, and the light transmitting area is used for forming a hollow area of the cathode layer.
Furthermore, the mask plate comprises a plurality of shielding areas arranged at intervals, the light-transmitting area is formed between two adjacent shielding areas, and the shielding areas are used for forming a cathode of the cathode layer.
Furthermore, the mask plate further comprises a plurality of second connecting bridges, two adjacent shielding areas are connected through at least one second connecting bridge, and the second connecting bridges are used for forming second connecting bridges of the cathode layer.
Further, a cathode layer of the flexible display panel is formed by adopting a mask, the mask comprises a light-transmitting area, and the cathode layer comprises a hollow-out area formed corresponding to the light-transmitting area.
Further, the "forming a cathode layer of a flexible display panel using a mask" further includes: the mask plate further comprises a plurality of shielding areas arranged at intervals, the light transmitting area is formed between every two adjacent shielding areas, and the cathode layer further comprises a cathode formed corresponding to the shielding areas.
Furthermore, the mask still includes a plurality of second connection bridges, and two adjacent sheltering areas are connected through at least one second connection bridge, the cathode layer still includes corresponding the first connection bridge that the second connection bridge formed, adjacent two the negative pole is through at least one the electrical property conduction is realized to first connection bridge.
According to the flexible display panel, the manufacturing method of the flexible display panel, the display device and the mask, the cathode layer forms the first hollow area, when the flexible display panel is bent, the first hollow area can effectively release stress of the flexible display panel, and the cathode layer is prevented from being broken or separated from the upper film layer and the lower film layer which are adjacent to the cathode layer due to bending.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained according to these drawings without creative efforts.
Fig. 1 is a schematic diagram of a display device according to a first embodiment of the present invention.
Fig. 2 is a schematic view of a stacked structure of a flexible display panel of the display device shown in fig. 1.
Fig. 3 is a partially enlarged schematic view of the flexible display panel shown in fig. 2.
Fig. 4 is a schematic diagram of a mask for making a cathode layer.
Fig. 5 is a schematic diagram of a display device according to a second embodiment of the invention.
Fig. 6 is a schematic diagram of a display device according to a third embodiment of the present invention.
Fig. 7 is a schematic diagram of a display device according to a fourth embodiment of the invention.
Fig. 8 is a flowchart of a method for manufacturing a flexible display panel according to a fifth embodiment of the present invention.
Fig. 9 is a schematic view of a mask according to a sixth embodiment of the present invention.
Fig. 10 is a flowchart of a method for manufacturing a flexible display panel according to a seventh embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, a display device 100 is provided according to a first embodiment of the invention. The display device 100 includes a flexible display panel 10. The display device 100 may be a product or a component having a display function, such as a tablet computer, a notebook computer, a television, and a navigator.
The flexible display panel 10 comprises a cathode layer 18, the cathode layer 18 comprising a first hollowed out area 180. Because the cathode layer 18 forms the first hollow-out area 180, when the flexible display panel 10 is bent, the first hollow-out area 180 can effectively release the stress of the flexible display panel 10, and the cathode layer 18 is prevented from being broken or separated from the upper and lower film layers adjacent to the cathode layer 18 due to bending. In the present embodiment, the cathode layer 18 is made of metal. It will be appreciated that cathode layer 18 may be made of other conductive materials, such as carbon nanotubes.
Further, the cathode layer 18 includes a plurality of cathodes 181 disposed at intervals and electrically connected to each other. The plurality of cathodes 181 are arranged in an array. The first hollow areas 180 are disposed between two adjacent cathodes 181, and are spaced apart from each other. The flexible display panel 10 may be bent about a bending axis 200. The cathode 181 has a substantially rectangular shape, and the long side of the cathode 181 is parallel to the bending axis 200, thereby reducing the impact on the cathode 181 when bent.
Cathode layer 18 further comprises a plurality of first connection bridges 185. The two adjacent cathodes 181 are electrically connected through at least one first connecting bridge 185. Wherein, a first end of the first connecting bridge 185 is connected with one cathode 181, and a second end of the first connecting bridge 185 is connected with the other cathode 181. Each first connecting bridge 185 is located between two first hollow areas 180. In this embodiment, the cathode 181 is formed in synchronization with the first connection bridge 185, and the cathode 181 and the first connection bridge 185 are formed by a plating process on the organic light emitting layer 17. In this embodiment, the patterned cathode layer 18 is formed by vapor deposition using a Fine Mask (Fine Mask). Since the cathode 181 and the first connecting bridge 185 are formed simultaneously, the number of process steps can be reduced, and the flexible display panel 10 can be prevented from being broken between the cathodes 181 during the bending process or after being bent for multiple times. In other embodiments, the cathode 181 and the first connection bridge 185 are formed by patterning the same conductive layer.
In one embodiment, a first hollow area 180 is disposed between two adjacent cathodes 181. The adjacent two cathodes 181 are connected by other conductive structures, for example, a wire.
The flexible display panel 10 further includes a plurality of pixel units 101. The plurality of pixel units 101 are arranged in an array. Each cathode 181 is disposed corresponding to one pixel unit 101. Each pixel unit 101 includes three pixel regions 102. The pixel region 102 includes a light-emitting region 103 and a non-light-emitting region 104 connected to the light-emitting region 103. The three pixel regions 102 include a red pixel region, a green pixel region, and a blue pixel region. In this embodiment, the pixel regions 102 are rectangular and have approximately the same light emitting area, it is understood that in other embodiments, the shape of each pixel region 102 may be changed accordingly according to actual light emitting needs, for example, the shape is circular or irregular such as parallelogram, it is also understood that the area of each pixel region 102 may be changed accordingly according to actual needs to meet different brightness needs, and the light emitting areas of the pixel regions may be the same or different.
In the present embodiment, the arrangement direction of the three pixel regions 102 in the same pixel unit 101 is parallel to the bending axis 200.
In an embodiment, referring to fig. 2, the flexible display panel 10 further includes a substrate 11, a plurality of thin film transistors 13, an anode layer 15, a pixel defining layer 16, an organic light emitting layer 17, and an encapsulation layer 19. The substrate 11, the thin film transistor 13, the anode layer 15, the pixel defining layer 16, the organic light emitting layer 17, the cathode layer 18, and the encapsulating layer 19 are sequentially stacked. The cathode layer 18 is provided between the organic light emitting layer 17 and the encapsulation layer 19.
Referring further to fig. 3, the package layer 19 includes a filling portion 191. The filling part 191 fills the first hollowed-out area 180. The side of the filling portion 191 is closely attached to the sidewall of the first hollow-out region 180, and the bottom of the filling portion 191 facing the organic light emitting layer 17 is closely attached to the organic light emitting layer 17, so that the encapsulation layer 19 and the organic light emitting layer 17 are engaged with each other through the first hollow-out region 180. Because the cathode layer 18 is coated between the encapsulation layer 19 and the organic light emitting layer 17, and the encapsulation layer 19 and the organic light emitting layer 17 are mutually engaged through the first hollow area 180, the connection strength between the cathode layer 18 and the organic light emitting layer 17 as well as the encapsulation layer 19 is enhanced, and the peeling of the cathode layer 18, the organic light emitting layer 17 and the encapsulation layer 19 caused by bending is reduced.
In this embodiment, the thin film transistor 13 has a top gate structure. The thin film transistor 13 includes an active layer 131, a gate insulating layer 132, a gate electrode 133, and source and drain electrodes 134. The active layer 131 is provided on the substrate 11. The gate insulating layer 132 is disposed on a side of the active layer 131 away from the substrate 11. The gate electrode 133 is disposed on the gate insulating layer 132 away from the active layer 131. The source and drain electrodes 134 contact the active layer 131. In one embodiment, the thin film transistor 13 may have a bottom gate structure.
The pixel defining layer 16 is typically made of an organic material. The pixel definition layer 16 defines a plurality of pixel units 101. The cathode 181 covers the pixel unit 101. In the light emitting region 103 of each pixel region 102, the organic light emitting layer 17, the cathode 181, and the anode layer 15 are included. The organic light emitting layer 17 is located between the cathode layer 18 and the anode layer 15 for generating light of a predetermined color to realize display. Alternatively, a part of the cathode layer 18, a part of the anode layer 15, and a part of the organic light emitting layer 17 constitute the organic light emitting diode. Each of the organic light emitting diodes is disposed corresponding to one of the thin film transistors 130. The thin film transistor 130 is used to drive the organic light emitting diode.
The flexible display panel 10 further includes a buffer layer 21, an interlayer dielectric layer 23, a passivation layer 25, and a planarization layer 27. The buffer layer 21 is provided between the active layer 131 and the substrate 11. The interlayer dielectric layer 23 is disposed on the gate electrode 133 and the gate insulating layer 132, the source/drain electrode 134 is disposed on the interlayer dielectric layer 23, the passivation layer 25 is disposed on the interlayer dielectric layer 23 and the source/drain electrode 134, the planarization layer 27 is disposed on the passivation layer 25, and the anode layer 15 is disposed on the planarization layer 27.
In fabricating the cathode layer 18 of the flexible display panel 10, referring to fig. 4, a mask 60 may be used to fabricate a patterned portion of the cathode layer 18 on the organic light emitting layer 17. The mask 60 includes a second hollow area 601, a non-hollow area 603, and a third hollow area 605, and the adjacent second hollow areas 601 are connected through the third hollow area 605. The second hollow area 601 is used for forming the cathode 181 of the cathode layer 18, the non-hollow area 603 is used for forming the first hollow area 180 of the cathode layer 18, and the third hollow area 605 is used for forming the first connecting bridge 185 of the cathode layer 18. In the present embodiment, a Fine mask (Fine mask) is used as the mask 60. It will be appreciated that the pattern and number of reticles 60 may be selected as desired to produce the desired pattern for cathode layer 18. In other embodiments, patterned cathode layer 18 may be formed using a single reticle 60.
Because the cathode layer 18 forms the first hollow-out area 180, when the flexible display panel 10 is bent, the first hollow-out area 180 can effectively release the stress of the flexible display panel 10, the cathode layer 18 is prevented from being broken or separated from the upper and lower film layers adjacent to the cathode layer 18 due to bending, and the problem that the cathode film layer obtained by the conventional cathode film coating method is not resistant to bending is solved.
The flexible display panel 10 of the present embodiment is manufactured by a multi-pixel covering method using the fine mask 60, and the cathode layer 18 includes the first hollow area 180. When flexible display panel 10 buckles, first fretwork area 180 can let stress release, and flexible display panel 10 is equipped with encapsulation layer 19 in cathode layer 18 and keeps away from substrate 11 one side, and encapsulation layer 19 interlocks each other through first fretwork area 180 and organic light emitting layer 17 to the negative pole 181 cladding of making the metal is inside, is favorable to reducing flexible display panel 10 and causes the rete to peel off when buckling.
In other embodiments, the cathode layer is not limited to have an organic light emitting layer and an encapsulation layer on two sides, such as a planarization layer or a dielectric layer, and the flexible display panel further includes a first layer and a second layer respectively located on two opposite sides of the cathode layer, where the first layer and the second layer are in direct contact through the first hollow area.
Referring to fig. 5, the structure of the flexible display device 30 according to the second embodiment of the present invention is substantially the same as the structure of the flexible display device 100 according to the first embodiment of the present invention, except that each cathode 381 is disposed corresponding to one pixel unit 301, and each pixel unit 301 includes six pixel regions 302. The six pixel regions 302 are divided into two groups, each group of pixel regions 302 includes a red pixel region, a green pixel region, and a blue pixel region, the two groups of pixel regions 302 of the same pixel unit 301 are arranged along a first direction, and the three pixel regions 302 of each group of pixel units 301 are arranged along a second direction perpendicular to the first direction.
Referring to fig. 6, a structure of a flexible display device 40 according to a third embodiment of the present invention is substantially the same as the structure of the flexible display device 100 according to the first embodiment of the present invention, except that each cathode 481 is disposed corresponding to one pixel unit 401, each pixel unit 401 includes nine pixel regions 402, the pixel units 401 are arranged at intervals along a first direction, the nine pixel regions 402 in the same pixel unit 401 are arranged along a second direction (parallel bending axis) perpendicular to the first direction, in this embodiment, the nine pixel regions 402 in the same pixel unit 401 include three red pixel regions, three green pixel regions and three blue pixel regions, and the nine pixel regions 402 are arranged in R, G, B, R, G, B, R, G, B. The plurality of cathodes 481 are arranged at intervals along a first direction, and the cathodes 481 extend along the second direction (parallel to the bending axis).
Referring to fig. 7, a flexible display device 50 according to a fourth embodiment of the present invention has a structure substantially the same as the flexible display device 100 according to the first embodiment of the present invention, and each cathode 581 is disposed corresponding to one pixel unit 501, except that the pixel unit 501 includes seven pixel regions 502 in the same column (parallel to the bending axis). Seven pixel regions 702 in the same pixel unit 501 are arranged in a first direction, and a plurality of pixel units 501 are arranged in a second direction perpendicular to the first direction. The cathodes 581 extend in the second direction, and a plurality of cathodes 581 are arranged at intervals in the first direction. The colors in the same pixel cell 501 are the same, and the colors in adjacent pixel cells 501 are different.
In summary, each cathode is disposed corresponding to one pixel unit, and the pixel unit includes at least one pixel region.
Referring to fig. 8, a fifth embodiment of the present invention further provides a method for manufacturing a flexible display panel, including the following steps:
step 801 is to sequentially form a thin film transistor, an anode layer, a pixel defining layer, and an organic light emitting layer on a substrate.
Step 802, forming a cathode layer of the flexible display panel on the organic light emitting layer by using a mask, forming a non-hollow area on the mask, and forming a first hollow area on the cathode layer corresponding to the non-hollow area.
In step 802, the "forming a cathode layer of a flexible display panel using a mask" further includes: the mask plate further comprises a plurality of second hollowed-out areas arranged at intervals, the non-hollowed-out area is formed between every two adjacent second hollowed-out areas, and the cathode layer further comprises a cathode formed corresponding to the second hollowed-out areas.
The mask plate further comprises a plurality of third hollowed-out areas, two adjacent second hollowed-out areas are communicated through at least one third hollowed-out area, the cathode layer further comprises a first connecting bridge corresponding to the third hollowed-out area, and two adjacent cathodes are electrically connected through at least one first connecting bridge.
Step 803, forming an encapsulation layer on the cathode layer, wherein the encapsulation layer fills the first hollow area.
In this embodiment, a cathode layer of the flexible display panel is formed by an evaporation process using a mask.
In an embodiment, a method for manufacturing a flexible display panel includes forming a cathode layer of the flexible display panel by using a mask, where the mask includes a non-hollow area, and the cathode layer includes a first hollow area formed corresponding to the non-hollow area.
Referring to fig. 9, a mask 70 for manufacturing a cathode layer of a flexible display panel is further provided in the sixth embodiment of the present invention. A patterned cathode layer is fabricated using a reticle 70. The mask 70 includes a shielding region 701 and a light-transmitting region 703, and adjacent shielding regions 701 are connected by a second connecting bridge 705. The shielding region 701 is used for forming a cathode of the cathode layer, the light-transmitting region 703 is used for forming a first hollow region of the cathode layer, and the second connecting bridge 705 is used for forming a first connecting bridge of the cathode layer. In this embodiment, the patterned cathode layer of the flexible display panel is formed by a photolithography process using the mask 70.
Referring to fig. 10, a seventh embodiment of the present invention further provides a method for manufacturing a flexible display panel, including the following steps:
step 901, a thin film transistor, an anode layer, a pixel defining layer, and an organic light emitting layer are sequentially formed on a substrate.
And 902, forming a cathode layer of the flexible display panel on the organic light-emitting layer by using a mask, wherein the mask comprises a light-transmitting area, and the cathode layer comprises a first hollow-out area formed corresponding to the light-transmitting area.
The mask plate further comprises a plurality of shielding areas arranged at intervals, the light transmitting area is formed between every two adjacent shielding areas, and the cathode layer further comprises a cathode formed corresponding to the shielding areas. The mask plate further comprises a plurality of second connecting bridges, two adjacent shielding areas are connected through at least one second connecting bridge, the cathode layer further comprises a second connecting bridge, the second connecting bridge forms a first connecting bridge, and two adjacent cathodes are electrically connected through at least one first connecting bridge.
Step 902 further comprises: coating a conductive layer on the organic light emitting layer; and the mask is adopted to pattern the conducting layer to synchronously form a plurality of shielding areas arranged at intervals, and the adjacent two cathodes are electrically conducted through at least one first connecting bridge.
Step 903, forming a packaging layer on the cathode layer, wherein the packaging layer fills the first hollow area.
According to the flexible display panel and the manufacturing method thereof, the display device and the mask, the cathode layer forms the hollow area, when the flexible display panel is bent, the stress of the flexible display panel can be effectively released by the hollow area, and the cathode layer is prevented from being broken or separated from the upper film layer and the lower film layer which are adjacent to the cathode layer due to bending.
While the foregoing is directed to the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention.