TO-BE-EVAPORATED SUBSTRATES, DISPLAY SUBSTRATES AND MANUFACTURING METHODS THEREOF

The present disclosure provides a to-be-evaporated substrate, a display substrate and a method of manufacturing a display substrate. The to-be-evaporated substrate may include: a substrate including a to-be-evaporated region and a non-evaporated region, where the non-evaporated region surrounds the to-be-evaporated region; a support pattern, disposed on the substrate and located in the non-evaporated region, where the support pattern includes a plurality of supporters for supporting a mask and further includes a first symmetrical pattern formed by a plurality of supporters, and the plurality of supporters forming the first symmetrical pattern are arranged along a perimeter of the to-be-evaporated region. The present disclosure can improve evaporation effect.

TECHNICAL FIELD

The present disclosure relates to the field of display technologies, and in particular to a to-be-evaporated substrate, a display substrate and a manufacturing method thereof.

BACKGROUND

At present, Organic Light-emitting Diode (OLED) display panels are mainly manufactured by evaporation. During an evaporation process, a Fine Metal Mask (FMM) is used to form light-emitting functional layers of sub-pixels, for example, R/G/B sub-pixels or the like, so that a material can be evaporated to a set position. But, the existing evaporation effect is poor.

SUMMARY

The object of the present disclosure is to provide a to-be-evaporated substrate, a display substrate and a manufacturing method thereof, so as to improve evaporation effect.

According to an aspect of the present disclosure, there is provided a to-be-evaporated substrate, including:

a substrate, including a to-be-evaporated region and a non-evaporated region, where the non-evaporated region surrounds the to-be-evaporated region: and

a support pattern, disposed on the substrate and located in the non-evaporated region, where the support pattern includes a first symmetrical pattern, the first symmetrical pattern is formed by a plurality of supporters, and the plurality of supporters forming the first symmetrical patterns are arranged along a perimeter of the to-be-evaporated region.

In some embodiments, the to-be-evaporated region is presented as a second symmetrical pattern, and a symmetrical axis of the first symmetrical pattern coincides with a symmetrical axis of the second symmetrical pattern.

In some embodiments, the first symmetrical pattern includes two symmetrical axes perpendicular to each other: the to-be-evaporated region is presented as a second symmetrical pattern, the second symmetrical pattern includes two symmetrical axes perpendicular to each other: and the two symmetrical axes of the first symmetrical pattern are respectively coincided with the two symmetrical axes of the second symmetrical pattern.

In some embodiments, the plurality of supporters each include a plurality of support columns arranged in a spacing.

In some embodiments, the number of to-be-evaporated regions is multiple, and at least one of the to-be-evaporated regions respectively includes a plurality of to-be-evaporated sub-regions arranged in a spacing.

In some embodiments, the at least one of the to-be-evaporated regions respectively includes two to-be-evaporated sub-regions arranged in a spacing, the two to-be-evaporated sub-regions are arranged symmetrically, and a symmetrical axis of the two to-be-evaporated sub-regions coincides with a symmetrical axis of the first symmetrical pattern.

In some embodiments, the at least one of the to-be-evaporated regions respectively includes two to-be-evaporated sub-regions arranged in a spacing, the two to-be-evaporated sub-regions are presented as two symmetrical patterns, symmetrical axes of two to-be-evaporated sub-regions in one of the at least one of the to-be-evaporated regions coincide with each other, and the symmetrical axes of the to-be-evaporated sub-regions coincide with a symmetrical axis of the first symmetrical pattern.

In some embodiments, the plurality of to-be-evaporated sub-regions in one of at least one of the to-be-evaporated regions are used to evaporate a same evaporation material.

In some embodiments, the number of to-be-evaporated regions is multiple, and the number of first symmetrical patterns is multiple, the to-be-evaporated regions are in one-to-one correspondence with the first symmetrical patterns, and two of the first symmetrical patterns share at least one of the supporters.

In some embodiments, two to-be-evaporated regions corresponding to the two first symmetrical patterns sharing at least one of the supporters are used to evaporate a same evaporation material or different evaporation materials.

In some embodiments, the supporters each include a support layer and a plurality of protrusions, the support layer is disposed on the substrate, and the plurality of protrusions are disposed on a side of the support layer away from the substrate, and the plurality of protrusions are arranged in a spacing.

In some embodiments, the substrate includes:

a base:

a pixel definition layer, disposed on a side of the base, where the pixel definition layer includes one or more pixel openings:

where the to-be-evaporated region includes one or more to-be-evaporated sub-regions, and the pixel opening forms the to-be-evaporated sub-region.

According to an aspect of the present disclosure, there is provided a display substrate, including:

a light emitter, disposed in the to-be-evaporated region.

According to an aspect of the present disclosure, there is provided a method of manufacturing a display substrate, including:

preparing a mask and the to-be-evaporated substrate:

forming a light emitter by performing evaporation on the to-be-evaporated region using the mask.

For a to-be-evaporated substrate, a display substrate and a method of manufacturing a display substrate in the present disclosure, when a film layer is formed by evaporation process, a mask is supported by a support pattern. A plurality of supporters in the support pattern are arranged along a perimeter of a to-be-evaporated region and further form a first symmetrical pattern, so as to improve support uniformity, helping to improve the thickness uniformity of the film layer formed by evaporation as well as evaporation effect.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Terms used herein are used to only describe a particular embodiment rather than limit the present disclosure. Unless otherwise defined, technical terms or scientific terms used in the present disclosure should have general meanings that can be understood by ordinary persons of skill in the art. “First” “second” or the like used in the specification and claims do not represent any sequence, quantity or importance, but distinguish different components. Similarly, “one” or “a” or the like do not represent quantity limitation, but represent at least one. “Multiple” or “a plurality” represents two or more. Unless otherwise stated, the words such as “front”, “rear”, “lower” and/or “upper” are used only for ease of descriptions rather than limited to one position or a spatial orientation. Unless otherwise stated, “include” or “contain” or the like is intended to refer to that an element or object appearing before “include” or “contain” covers an element or object or its equivalents listed after “include” or “contain” and does not preclude other elements or objects. “Connect” or “connect with” or the like is not limited to physical or mechanical connection but includes direct or indirect electrical connection. The singular forms such as “a”, “said”, and “the” used in the present disclosure and the appended claims are also intended to include plural forms, unless the context clearly indicates otherwise. It is also to be understood that the term “and/or” as used herein refers to and includes any or all possible combinations of one or more associated listed items.

The present disclosure provides a to-be-evaporated substrate, which is used to manufacture a display substrate or the like. As shown inFIGS.1and13, the to-be-evaporated substrate may include a substrate and a support pattern.

As shown inFIG.1, the substrate may include one or more to-be-evaporated regions1and a non-evaporated region2. The non-evaporated region2surrounds the one or more to-be-evaporated regions1. The support pattern is disposed on the substrate and located in the non-evaporated region2. The support pattern includes a plurality of supporters3for supporting a mask. The support pattern may include one or more first symmetrical patterns100. The first symmetrical pattern100is formed by a plurality of supporters3, and the plurality of supporters3forming the first symmetrical pattern100are arranged along a perimeter of the to-be-evaporated region1.

In the to-be-evaporated substrate of the present disclosure, when a film layer is formed by evaporation process, the support pattern is configured to support the mask. A plurality of supporters3in the support pattern are arranged along a perimeter of the to-be-evaporated regions1, and further form the first symmetrical patterns100, so as to improve support uniformity, helping to improve the thickness uniformity of the film layer formed by evaporation as well as evaporation effect.

The parts of the to-be-evaporated substrate will be further elaborated below in combination with specific embodiments.

If the to-be-evaporated substrate is used to manufacture a display substrate, the substrate may include a base4and a pixel definition layer7as shown inFIG.13. The base4may be a rigid base, where the rigid base may be a glass base or a Polymethyl methacrylate (PMMA) base or the like. In some embodiments, the base4may be a flexible base, where the flexible base may be a Polyethylene terephthalate (PET) base, or a Polyethylene naphthalate two formic acid glycol ester (PEN) base or a Polyimide (PI) base.

The pixel definition layer7may be disposed on the base4. In some embodiments, the substrate may further include a drive circuit layer5and a planarization layer6. The drive circuit layer5may be disposed on the base4. The drive circuit layer5may include a plurality of drive transistors. The drive transistors may be thin film transistors, which is not limited in the embodiments. The thin film transistor may be a top-gate thin film transistor. In some embodiments, the thin film transistor may be a bottom-gate thin film transistor. With the thin film transistor as the top-gate thin film transistor, the drive circuit layer5may include an active layer, a gate insulation layer, a gate electrode, an interlayer insulation layer, a source electrode and a drain electrode. The active layer may be disposed on the base4. The gate insulation layer may be disposed on the base4and covered on the active layer. The gate electrode may be disposed on a side of the gate insulation layer away from the base4. The interlayer insulation layer may be disposed on the gate insulation layer and covered on the gate electrode. The source electrode and the drain electrode may be disposed on the interlayer insulation layer and connected to the active layer through via holes penetrating through the interlayer insulation layer and the gate insulation layer. The planarization layer6may be disposed on a surface of the drive circuit layer5away from the base4and covered on the source electrode and the drain electrode of the drive transistor. The pixel definition layer7may be disposed on the planarization layer6. The pixel definition layer7may include one or more pixel openings701. The one or more pixel openings701may include a plurality of pixel openings arranged in an array. The pixel opening701may be a tetragon, a pentagon or a hexagon or the like, which is not limited herein. In some embodiments, the pixel openings701may be used to evaporate a light-emitting material. The plurality of pixel openings701may include a first-type pixel opening, a second-type pixel opening and a third-type pixel opening.

As shown inFIG.1, the substrate may include one or more to-be-evaporated regions1and a non-evaporated region2. The number of the one or more to-be-evaporated regions1may be one. In some embodiments, the number of the one or more to-be-evaporated regions1may be multiple, and the plurality of to-be-evaporated regions are arranged in a spacing. The non-evaporated region2surrounds the to-be-evaporated regions1. In an embodiment of the present disclosure, as shown inFIG.1, one to-be-evaporated region1may only include one to-be-evaporated sub-region101. In another embodiment of the present disclosure, as shown inFIG.2, one to-be-evaporated region1may include a plurality of to-be-evaporated sub-regions101arranged in a spacing. For example, one to-be-evaporated region1may include two to-be-evaporated sub-regions101arranged in a spacing. In other embodiments of the present disclosure, as shown inFIG.3, the substrate may include a plurality of to-be-evaporated regions1, where at least one of the plurality of to-be-evaporated regions1only includes one to-be-evaporated sub-region1respectively, and at least one of the plurality of to-be-evaporated regions1may respectively include two to-be-evaporated sub-regions101arranged in a spacing. A region of the pixel definition layer7in one pixel opening701may form one to-be-evaporated sub-region101. The to-be-evaporated sub-region101may be used to evaporate a desired evaporation material which may be a light-emitting material, for example, a red light-emitting material, a green light-emitting material or a blue light-emitting material. A plurality of to-be-evaporated sub-regions101in one to-be-evaporated region1may be used to evaporate a same evaporation material, or different evaporation materials.

For example, as shown inFIGS.3,5,6, and9to12, a plurality of to-be-evaporated regions1may include a first-type to-be-evaporated region1A, a second-type to-be-evaporated region1B, and a third-type to-be-evaporated region1C. A plurality of first-type to-be-evaporated regions1A, a plurality of second-type to-be-evaporated regions1B and a plurality of third-type to-be-evaporated regions1C are provided. The plurality of first-type to-be-evaporated regions1A are arranged in an array, the plurality of second-type to-be-evaporated regions1B are arranged in an array and the plurality of third-type to-be-evaporated regions1C are arranged in an array. The first-type to-be-evaporated regions1A are used to evaporate a red light-emitting material, the second-type to-be-evaporated regions1B are used to evaporate a blue light-emitting material, and the third-type to-be-evaporated regions1C are used to evaporate a green light-emitting material. InFIG.3, the third-type to-be-evaporated region1C includes two to-be-evaporated sub-regions101. InFIGS.5and6, the second-type to-be-evaporated region1B includes two to-be-evaporated sub-regions101.

The to-be-evaporated region1may be presented as a second symmetrical pattern, and a symmetrical axis of the second symmetrical pattern may be parallel to the to-be-evaporated substrate. As shown inFIG.1, for example, one to-be-evaporated region1only includes one to-be-evaporated sub-region101and the pixel opening701forms the to-be-evaporated sub-region101. In this case, one to-be-evaporated sub-region101may be presented as a second symmetrical pattern (a symmetrical axis is L1or L2inFIG.1) in the present disclosure. That is, one pixel opening701is presented as a second symmetrical pattern, such that the to-be-evaporated region1including one to-be-evaporated sub-region101is presented as a second symmetrical pattern. As shown inFIGS.2,7and8, for example, one to-be-evaporated region1includes two to-be-evaporated sub-regions101and two pixel openings701form the two to-be-evaporated sub-regions101. In this case, the two to-be-evaporated sub-regions101may be arranged symmetrically (a symmetrical axis is L2inFIG.2) in the present disclosure. That is, the two pixel openings701corresponding to the two to-be-evaporated sub-regions101are arranged symmetrically, such that the to-be-evaporated region1including two to-be-evaporated sub-regions101is presented as a second symmetrical pattern. In other embodiments of the present disclosure, as shown inFIGS.2,7and8, the two to-be-evaporated sub-regions101may be presented as two axisymmetric patterns, and symmetrical axes of the two to-be-evaporated sub-regions101coincide with each other (the symmetrical axes each are L1inFIG.2). That is, the two pixel openings701may be presented as two axisymmetric patterns, and symmetrical axes of the two pixel openings701coincide with each other, such that the to-be-evaporated region1including two to-be-evaporated sub-regions101is presented as a second symmetrical pattern.

As shown inFIGS.1,2,7and8, the second symmetrical pattern may include two symmetrical axes which are perpendicular to each other (two symmetrical axes are L1and L2). For example, one to-be-evaporated region1includes two to-be-evaporated sub-regions101. In this case, each of the two to-be-evaporated sub-regions101is presented as a axisymmetric pattern, and symmetrical axes of the two to-be-evaporated sub-regions101coincide with each other and meanwhile, the two to-be-evaporated sub-regions101are further symmetrically arranged. Thus, the second symmetrical pattern includes two symmetrical axes perpendicular to each other.

The support pattern is disposed on the substrate and located in the non-evaporated region2. In some embodiments, the support pattern may be disposed in a region of the pixel definition layer7outside the pixel openings701. The support pattern may include a plurality of supporters3. The supporters3are configured to support a mask used in an evaporation process. As shown inFIGS.1and2, the support pattern may include one or more first symmetrical patterns100, the symmetrical axis of the first symmetrical pattern100may be parallel to the to-be-evaporated substrate. The first symmetrical pattern100is formed by a plurality of supporters3which are arranged along a perimeter of the to-be-evaporated region1, so as to improve support uniformity. In some embodiments, the first symmetrical pattern100may include two symmetrical axes, where the two symmetrical axes may be perpendicular to each other and parallel to the to-be-evaporated substrate.

As shown inFIGS.1and2, the symmetrical axis of the first symmetrical pattern100may coincide with the symmetrical axis of the second symmetrical pattern. In some embodiments, for example, the first symmetrical pattern100and the second symmetrical pattern include two symmetrical axes respectively, and the two symmetrical axes of the first symmetrical pattern100are respectively coincided with the two symmetrical axes of the second symmetrical pattern (the two symmetrical axes of the first symmetrical pattern100also are L1and L2). “Two symmetrical axes coincide with each other” in the present disclosure refers to the two symmetrical axes are in a same straight line.

As shown inFIGS.3to6, if a plurality of to-be-evaporated regions1and a plurality of first symmetrical patterns100are disposed, the plurality of first symmetrical patterns100may be in one-to-one correspondence with the plurality of to-be-evaporated regions1, and two of the plurality of first symmetrical patterns100share at least one of the supporters3, thus reducing the number of the supporters3and saving the costs. As shown inFIGS.3to6, symmetrical axes of a plurality of to-be-evaporated regions1arranged along an X direction are in a same straight line. As shown inFIGS.3and4, two adjacent first symmetrical patterns100arranged along the X direction share at least one of the supporters3. InFIG.3, two to-be-evaporated regions1corresponding to two first symmetrical patterns100sharing at least one of the supporters3are used to evaporate different evaporation materials. InFIG.4. two to-be-evaporated regions1corresponding to two first symmetrical patterns100sharing at least one of the supporters3are used to evaporate a same evaporation material.

In some embodiments, inFIG.3, a straight line L3is perpendicular to the X direction. Centers of a plurality of support columns301arranged along an extension direction of the straight line L3are all located on the straight line L3, and centers of a plurality of to-be-evaporated regions1arranged along the extension direction of the straight line L3are located on the straight line L3. InFIG.5, a straight line L4is perpendicular to the X direction, and centers of a plurality of support columns301arranged along an extension direction of the straight line L4are all located on the straight line L4. InFIG.9, centers of a plurality of to-be-evaporated regions1arranged along an extension direction of a straight line L5are located on the straight line L5, and centers of a plurality of to-be-evaporated regions1arranged along an extension direction of a straight line L6are located on the straight line L6, where the straight line L5is perpendicular to the straight line L6. In some embodiments, the support columns301located on both sides of the straight line L5are arranged symmetrically with the straight line L5as symmetrical axis, and the to-be-evaporated regions1located on both sides of the straight line L5are arranged symmetrically with the straight line L5as symmetrical axis. The support columns301located on both sides of the straight line L6are arranged symmetrically with the straight line L6as symmetrical axis, and the to-be-evaporated regions1located on both sides of the straight line L6are arranged symmetrically with the straight line L6as symmetrical axis. Compared withFIG.9, the support columns301inFIG.10rotate 90° clockwise around the centers of the support columns301; compared withFIG.10, the support columns301inFIG.11rotate 45° clockwise around the centers of the support columns301; compared withFIG.11, the support columns301inFIG.12rotate 90° clockwise around the centers of the support columns301.

In some embodiments, one supporter3in the present disclosure may only include one support column301, which can be called original support column in the present disclosure. As shown inFIG.13, in the present disclosure, the original support column may be replaced with a plurality of spaced-apart support columns301with smaller cross sectional area. Compared with the original support column, these support columns301with smaller cross sectional area can reduce a frictional force between the support columns301and the mask and reduce foreign matters produced by scratching between the mask and the support columns301, thereby increasing the product yield and extending the product life. In other embodiments of the present disclosure, as shown inFIG.14, the supporter3may include a support layer302and a plurality of protrusions303. The support layer302may be disposed in a region of the pixel definition layer7outside the pixel opening701. The plurality of protrusions303are disposed on a side of the support layer302away from the base, and the plurality of protrusions303are arranged in a spacing. The protrusion303has a smaller cross sectional area than the original support column, so that foreign matters produced by scratching between the mask and the support columns301can further be reduced.

An embodiment of the present disclosure further provides a display substrate, which may include a light emitter and the to-be-evaporated substrate mentioned in any one of the above embodiments. The light emitter may be disposed in the to-be-evaporated region1. In some embodiments, the light emitter may be disposed in the above to-be-evaporated sub-region101.

An embodiment of the present disclosure further provides a method of manufacturing a display substrate. The method may include: preparing a mask and the to-be-evaporated substrate mentioned in any one of the above embodiments; forming a light emitter by performing evaporation on the to-be-evaporated region1using the mask.

The to-be-evaporated substrate, the display substrate and the method of manufacturing a display substrate in the present disclosure all belong to a same concept, and their relevant details and beneficial effects can be referred to each other. Therefore, no redundant descriptions are made herein.

The above descriptions are made merely to preferred embodiments of the present disclosure rather than intended to limit the present disclosure in any manner. Although the present disclosure is made with preferred embodiments as above, these preferred embodiments are not used to limit the present disclosure. Those skilled in the art may make some changes or modifications to the technical contents of the present disclosure as equivalent embodiments without departing from the scope of the technical solution of the present disclosure. Any simple changes, equivalent changes or modifications made to the above embodiments based on the technical essence of the present disclosure without departing from the contents of the technical solution of the present disclosure shall all fall within the scope of protection of the present disclosure.