Display panel, manufacturing method of display panel, and display apparatus

Disclosed are a display panel, a manufacturing method of the display panel, and a display apparatus. The display panel includes: a base substrate; and a pixel circuit film layer disposed on the base substrate. The display panel has a plurality of island regions, opening regions between the adjacent island regions, and bridge regions connecting adjacent island regions. Where the plurality of island regions are provided therein the base substrate and the pixel circuit film layer; the opening regions each is provided with a first via hole, and the first via hole runs through the base substrate and the pixel circuit film layer. The display panel further comprises: deformable components each filling the first via hole; where each deformable component comprises an elastic material.

CROSS REFERENCE TO RELATED APPLICATION

This application is based on and claims priority under 35 U.S.C 119 to Chinese Patent Application No. 202011515440.2, filed on Dec. 21, 2020, in the China National Intellectual Property Administration. The entire disclosure of the above application is incorporated herein by reference.

FIELD

The application relates to the technical field of display, in particular to a display panel, a manufacturing method of the display panel and a display apparatus.

BACKGROUND

Stretchable display, as a next generation novel morphologic display technology of flexible display, can be applied in the more flexible and imaginative application scenarios.

SUMMARY

Embodiments of the disclosure provide a display panel, a manufacturing method of the display panel, and a display apparatus.

An embodiment of the disclosure provides a display panel. The display panel includes: a base substrate; and a pixel circuit film layer disposed on the base substrate. The display panel has a plurality of island regions, opening regions between the adjacent island regions, and bridge regions connecting adjacent island regions. Where the plurality of island regions are provided therein the base substrate and the pixel circuit film layer; the opening regions each is provided with a first via hole, and the first via hole runs through the base substrate and the pixel circuit film layer. The display panel further comprises: deformable components each filling the first via hole; where each deformable component comprises an elastic material.

An embodiment of the disclosure provides a manufacturing method of the display panel, where the display panel includes: a plurality of island regions, opening regions located between the adjacent island regions, and bridge regions connecting the adjacent island regions. The method includes: providing a base substrate, forming a pixel circuit film layer on the base substrate, and forming first via holes penetrating the base substrate and the pixel circuit film layer in the opening regions; and filling each first via hole with an elastic material to form a deformable structure.

An embodiment of the disclosure provides a display apparatus, including a display panel. The display panel includes a base substrate; and a pixel circuit film layer disposed on the base substrate. The display panel has a plurality of island regions, opening regions between the adjacent island regions, and bridge regions connecting adjacent island regions. Where the plurality of island regions are provided therein the base substrate and the pixel circuit film layer; the opening regions each is provided with a first via hole, and the first via hole runs through the base substrate and the pixel circuit film layer. The display panel further comprises: deformable components each filling the first via hole; where each deformable component comprises an elastic material.

DETAILED DESCRIPTION OF THE EMBODIMENTS

In order to make the objectives, technical solutions, and advantages of the embodiments of the disclosure clearer, the technical solutions in embodiments of the disclosure will be clearly and fully described in combination with the accompanying drawings of the embodiments of the disclosure. It is apparent that the described embodiments are some, but not all, embodiments of the disclosure. Also, embodiments and features in the embodiments of the disclosure may be combined with one another without conflict. Based on the described embodiments of the disclosure, all other embodiments attainable by those ordinarily skilled in the art without involving any inventive effort are within the scope of the disclosure.

Unless otherwise defined, the technical terms or scientific terms used in the disclosure shall have the usual meanings understood by those of ordinary skill in the art to which the disclosure belongs. “First”, “second” and similar words used in the disclosure do not indicate any order, quantity or importance, but are only used to distinguish different components. “Comprise” or “include” or other similar words mean that the element or item appearing before the word covers elements or items listed after the word and their equivalents, but does not exclude other elements or items. “Connecting” or “connected” or other similar words are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect.

It should be noted that the dimensions and shapes of the various figures in the drawings are not to scale and are only intended to be merely illustrative of the disclosure. The same or similar reference numerals refer to the same or similar elements or elements having the same or similar functions throughout.

The inventors find that there are many ways to achieve stretchable display, in which after a display pixel unit is prepared on a flexible substrate, various opening are designed on the substrate so as to achieve the stretchability of display. This method is a feasible solution which is currently most likely to be into mass production. However, by providing openings in the substrate, the stretch strength of the substrate is inevitably reduced while the stretch performance of display is improved. A large number of simulation and experimental results show that there is a stress concentration phenomenon at the corners of the opening during stretching. Therefore, fracture cracks first appear at the corners of the opening during stretching. At present, for the stretchable display provided with this kind of opening, the maximum stretchable strain cannot exceed 3%, which limits the stretchability of a stretchable display device and increases the risk of failure of the display device.

An embodiment of the disclosure provides a display panel, as shown inFIG.1,FIG.2, andFIG.3.FIG.2andFIG.3which are cross-sectional views in a direction AA′ inFIG.1. The display panel includes: a base substrate1, and a pixel circuit film layer2disposed on the base substrate1. The display panel has a plurality of island regions S1, opening regions S3between the adjacent island regions S1, and bridge regions S2connecting the adjacent island regions S1. Where the plurality of island regions S1are provided therein the base substrate1and the pixel circuit film layer2; the opening regions S3each is provided with a first via hole3, and the first via hole3runs through the base substrate1and the pixel circuit film layer2. The display panel further includes: deformable components4each filling the first via hole3; where each deformable component4comprises an elastic material.

The display panel provided by the embodiment of the disclosure may be applied to a stretchable display product. In some embodiments, a material of the base substrate includes, for example, polyimide (PI).

In the display panel provided by the embodiments of the disclosure, each opening region is provided with the deformable component filling the first via hole, and each deformable component includes the elastic material, so that the edges of the film layers run through by the first via holes are covered by the elastic materials, so as not to crack during the stretching process, thereby improving the stretch strength and stretch deformation of the display panel, and improving the stretch performance of the display panel.

In some embodiments, as shown inFIG.1, each island region S1has at least one pixel, and each pixel includes three sub-pixel regions27.

In some embodiments, each pixel may include a red sub-pixel region, a green sub-pixel region, and a blue sub-pixel region. The bridge regions S2are provided therein signal lines (not shown) connecting the pixels in the adjacent island regions S1. The signal lines may be gate lines, data lines, or power lines, etc.

In some embodiments, each island region S1may be rectangular, each opening region S3may be strip-shaped, and each strip-shaped opening region S3may be located in a gap between the corresponding two adjacent island regions S1, and has the same extension direction as the side edges of the island regions S1.

In some embodiments, as shown inFIG.1, each island region may include four pixels.

In some embodiments, the display panel provided by the embodiment of the disclosure may be, for example, an electroluminescent display panel. The electroluminescent display panel may be, for example, an organic light emitting diode display panel, an inorganic light emitting diode display panel, or a quantum dot light emitting diode display panel. The organic light emitting diode display panel may be, for example, an active matrix OLED (AMOLED) or a passive matrix OLED (PMOLED).

In some embodiments, a pixel circuit of the AMOLED includes, for example, a thin film transistor and a light emitting device. As shown inFIG.2, the pixel circuit film layer2includes: a buffer layer5, an active layer6, a first gate insulating layer7, a first metal layer8, a second gate insulating layer9, a second metal layer10, an interlayer dielectric layer11, a third metal layer12, a first planarization layer13, a fourth metal layer14, a second planarization layer15, a pixel definition layer16, an anode17, a light emitting functional layer18, a cathode19, and an encapsulation layer20. The first metal layer8includes a gate21and a first electrode22of a capacitor. The second metal layer10includes a second electrode23of the capacitor. The third metal layer12may specifically include a source24and a drain25. The fourth metal layer14may include an overlap electrode26, and the overlap electrode26is connected with the drain25, for example. The encapsulation layer includes, for example, an inorganic encapsulation layer and an organic encapsulation layer disposed on the inorganic encapsulation layer. In some embodiments, besides the signal lines connecting the pixels in the adjacent island regions, each bridge region is further provided therein insulating layers such as the first gate insulating layer, the second gate insulating layer, the interlayer dielectric layer, the first planarization layer, and the encapsulation layer.

In some embodiments, as shown inFIG.3, the pixel circuit film layer2of the PMOLED structure includes: a buffer layer5, a fifth metal layer28, a first insulating layer29, a sixth metal layer30, a second planarization layer15, an anode17, a light emitting functional layer18, a cathode19, and an encapsulation layer20. The sixth metal layer30includes a connecting lead connecting the fifth metal layer28with the anode17.

In some embodiments, the elastic materials may be transparent elastic materials or opaque elastic materials.

In some embodiments, the elastic modulus of the elastic materials is 10 KPa to 20 MPa. That is, in the display panel provided by the embodiment of the disclosure, the elastic materials included in the deformable components have a relatively low elastic modulus, and thus great deformation can be caused by applying a small stress to the deformable components, which further improves the stretch performance of the display panel.

In some embodiments, the elastic material includes one or a combination of the following: polydimethylsiloxane (PDMS), thermoplastic polyurethanes (TPU) and rubber.

In some embodiments, each deformable component further includes: a plurality of particles uniformly dispersed in the elastic material, and the particles include: water absorbent particles and/or readily oxidizable particles.

In the display panel provided by the embodiment of the disclosure, the deformable components further include the water absorbent particles and/or readily oxidizable particles uniformly dispersed in the elastic materials, and the particles easily react with water and oxygen, so that the erosion of water and oxygen in the external environment on the display panel can be further reduced, and the encapsulation performance of the display panel is improved while the stretch performance of the stretchable display panel is improved.

In some embodiments, the water absorbent particles include, for example, calcium fluoride and lithium fluoride. The readily oxidizable particles include, for example, active metals such as magnesium and silver.

In some embodiments, a material of the particles includes one or a combination of the following: calcium fluoride, lithium fluoride, magnesium and silver.

In some embodiments, the diameter of the particles is: 10 nm to 10 μm.

In some embodiments, as shown inFIGS.4and5, the display panel further includes: a first protective layer31on a side, facing away from the base substrate1, of the pixel circuit film layer2, and a second protective layer32on a side, facing away from the pixel circuit film layer2, of the base substrate1.

The first protective layers31and the second protective layers32cover the deformable components4.

In some embodiments, the first protective layers and the second protective layers include elastic materials.

In other words, the first protective layers and the second protective layers are elastic film layers. In the display panel provided by the embodiment of the disclosure, the first protective layers and the second protective layers include the elastic materials, and cover the deformable components, that is, the edges of the first via holes are completely covered by the elastic materials, thereby more effectively preventing the film layers run through by the first via holes from cracking at the corners of the first via holes, and further improving the stretch performance of the display panel.

In some embodiments, the first protective layers and the second protective layers include transparent elastic materials, so as to avoid affecting the transmittance of the display panel.

In some embodiments, the first protective layers and the second protective layers include the same elastic materials as the deformable components.

In some embodiments, the elastic moduli of the elastic materials in the first protective layers and the second protective layers are 10 KPa to 20 MPa, that is, the elastic materials included in the first protective layers and the second protective layers have a relatively low elastic moduli, and thus great deformation can be caused by applying a small stress to the deformable components, which further improves the stretch performance of the display panel.

In some embodiments, as shown inFIGS.6and7, the display panel further includes: a first electrode layer33between the first protective layer31and the deformable component4, and a second electrode layer34between the second protective layer32and the deformable component4.

In each opening region S3, an orthographic projection of the first electrode layer33on the base substrate overlaps an orthographic projection of the second electrode layer34on the base substrate, and the first electrode layer33and the second electrode layer34are in contact with the deformable component4.

FIG.6uses the AMOLED as an example for illustration, andFIG.7uses the PMOLED as an example for illustration.

It should be noted that, in the display panel provided by the embodiment of the disclosure, each opening region is provided with the first electrode layer and the second electrode layer respectively located on both sides of the deformable component, and the first electrode layers and the second electrode layers are in contact with the deformable components. Therefore, in each opening region, the first electrode layer, the second electrode layer, and the deformable component constitute a sensing unit. The operation of applying force, such as touching, stretching, and twisting the display panel, will cause deformation of the display panel. When the display panel is deformed, correspondingly, the deformable components are also deformed, so that each sensing unit formed by the first electrode layer, the second electrode layer and the deformable component can detect the deformation. For example, electrical signals can be provided for the first electrode layers and the second electrode layers. When a signal fed back by each sensing unit changes, it is considered that a region corresponding to the sensing unit is deformed, and deformation parameters such as stress and strain can be determined according to the feedback signal. Therefore, the display panel provided by the embodiment of the disclosure can realize stress and strain detection. When touch occurs, a region, corresponding to the touch position, of the display panel is deformed, causing the deformable components to deform, so that the touch position can be determined according to the deformed position, so as to realize detection of the touch.

In the display panel provided by the embodiment of the disclosure, each sensing unit is constituted by the first electrode layer, the second electrode layer and the deformable component, and when the deformation of the display panel causes the deformable components to deform, the deformation can be detected, thereby realizing detection on stress, strain, touch, etc., increasing the functions of the display panel and increasing the disclosure scenarios of the display panel.

In some embodiments, as shown inFIGS.6,7,8and9, the first electrode layer33includes: first electrodes35corresponding to the deformable components in one-to-one correspondence, and first connecting leads (not shown) electrically connected with the first electrodes35. A projection of each first electrode35on the base substrate1overlaps a projection of the corresponding deformable component4on the base substrate1.

In some embodiments, as shown inFIGS.6and7, the second electrode layer34includes a planar electrode36disposed on an entire surface.

The second electrode layer further includes a second connecting lead electrically connected with the planar electrode.

Alternatively, in some embodiments, as shown inFIGS.8and9, the second electrode layer34includes second electrodes39corresponding to the deformable components in one-to-one correspondence, and second connecting leads electrically connected with the second electrodes39. An orthographic projection of each first electrode35on the base substrate1overlaps an orthographic projection of the corresponding second electrode39on the base substrate1.

In some embodiments, materials of the first electrode layers and the second electrode layers may include metal materials, and may also include materials such as carbon nanotubes, graphene, and metal nanowires.

In some embodiments, the first electrode layers, the deformable components, and the second electrode layers may constitute capacitive sensing units. By changing the area or distance between each first electrode layer and the corresponding second electrode layer, stress and strain can be detected, or, touch can be detected.

Alternatively, in some embodiments, the first electrode layers, the deformable components, and the second electrode layers may constitute piezoresistive sensing units, and when the deformable components are deformed, resistances of the piezoresistive sensing units change.

When the first electrode layers, the deformable components, and the second electrode layers constitute the piezoresistive sensing units, in some embodiments, a deformable structure further includes: conductive portions uniformly dispersed in the elastic materials.

In some embodiments, the conductive portions may be conductive particles, and the conductive particles may be, for example, metal particles or carbon black particles. The size of the conductive particles may be, for example, 10 nm to 1 μm. The conductive portions may also be conductive fibers, and the conductive fibers may be, for example, carbon nanotubes or graphene.

In some embodiments, the conductive portions include one or a combination of the following: metal particles, carbon black particles, carbon nanotubes, and graphene.

In some embodiments, as shown inFIGS.6and7, the display panel further includes: a first encapsulation layer37between the first electrode layer33and the pixel circuit film layer2, and a second encapsulation layer38between the second electrode layer34and the base substrate1. The first via hole3also runs through the first encapsulation layer37and the second encapsulation layer38. The first encapsulation layer37and the second encapsulation layer38include elastic materials.

It should be noted that when the display panel includes a sensor structure, the first encapsulation layers, the second encapsulation layers and the deformable structures all include elastic materials, so that the edges of the base substrate and the pixel circuit film layer run through by the first via holes are completely covered by the elastic materials, thereby more effectively preventing the base substrate and the pixel circuit film layer run through by the first via holes from cracking at the corners of the first via holes, and further improving the stretch performance of the display panel.

In some embodiments, the first encapsulation layers and the second encapsulation layers include transparent elastic materials, so as to avoid affecting the transmittance of the display panel.

In some embodiments, the first encapsulation layers and the second encapsulation layers include the same elastic materials as the deformable components.

In some embodiments, elastic moduli of the elastic materials in the first encapsulation layers and the second encapsulation layers are 10 KPa to 20 MPa. In other words, the elastic materials included in the first encapsulation layers and the second encapsulation layers have low elastic moduli, and thus great deformation can be caused by applying a small stress to the deformable components, which further improves the stretch performance of the display panel.

In some embodiments, when the display panel includes the sensor structure, the first protective layers and the second protective layers covering the deformable components may be inorganic film layers or organic film layers, and the thickness of the first protective layers and the second protective layers may be, for example, 20 nm to 2000 nm.

Based on the same inventive concept, an embodiment of the disclosure also provides a manufacturing method of the display panel including: a plurality of island regions, opening regions located between the adjacent island regions, and bridge regions connecting the adjacent island regions. As shown inFIG.10, the method includes:

S101: providing a base substrate;

S102: forming a pixel circuit film layer on the base substrate, and forming first via holes running through the base substrate and the pixel circuit film layer in the opening regions; and

S103: filling each first via hole with an elastic material to form a deformable component.

In the manufacturing method of the display panel provided by the embodiment of the disclosure, the opening regions are provided with deformable components filling the first via holes, and the deformable components include the elastic materials, so that the edges of the film layers run through by the first via holes are covered by the elastic materials, so as not to crack during the stretching process, thereby improving the stretch strength and stretch deformation of the display panel, and improving the stretch performance of the display panel.

In some embodiments, when the display panel is an AMOLED panel, forming the pixel circuit film layer on the base substrate in S102specifically includes:

forming a buffer layer, an active layer, a first gate insulating layer, a first metal layer, a second gate insulating layer, a second metal layer, an interlayer dielectric layer, a third metal layer, a first planarization layer, a fourth metal layer, and a second planarization layer are sequentially on the base substrate;

forming a pixel definition layer and an anode on the second planarization layer; and

forming a light emitting functional layer, a cathode, and an encapsulation layer sequentially on the anode.

In some embodiments, when the display panel is a PMOLED panel, forming the pixel circuit film layer on the base substrate in step102specifically includes:

forming a buffer layer, a fifth metal layer, a first insulating layer, a sixth metal layer, and a second planarization layer sequentially on the base substrate;

forming a pixel definition layer and an anode on the second planarization layer; and

forming a light emitting functional layer, a cathode, and an encapsulation layer sequentially on the anode.

In some embodiments, filling the first via holes with the elastic materials in S103includes:

injecting the elastic materials into the first via holes by using a pouring or spraying or knife-coating process.

In some embodiments, the method further includes: the elastic materials are heated and dried, and cured.

In some embodiments, after the first via holes are filled with the elastic materials to form the deformable structure, the method further includes:

forming a first protective layer covering the deformable structure on a side, facing away from the corresponding base substrate, of the pixel circuit film layer; and

forming a second protective layer covering the deformable structure on a side, facing away from the corresponding pixel circuit film layer, of the base substrate.

In some embodiments, the first protective layers and the second protective layers include elastic materials.

In some embodiments, the elastic materials may be coated by a knife-coating or liquid self-leveling process, and then when the temperature is lower than 100° C., the elastic materials are heated and dried and cured. In some embodiments, the heating and drying and curing processes of the deformable component, the first protective layers and the second protective layers may be performed in the same process flow.

In some embodiments, before the first protective layer covering the deformable structure is formed on the side, facing away from the corresponding base substrate, of the pixel circuit film layer, the method further includes:

forming a first electrode layer in contact with the deformable component on the side, facing away from the corresponding base substrate, of the pixel circuit film layer; and

before the second protective layer covering the deformable structure is formed on the side, facing away from the corresponding pixel circuit film layer, of the base substrate, the method further includes:

forming a second electrode layer in contact with the deformable component on the side, facing away from the corresponding pixel circuit film layer, of the base substrate.

When the display panel includes the first electrode layers and the second electrode layers, before the first via holes are filled with the elastic materials to form the deformable structure, the method further includes:

forming a first encapsulation layer exposing the opening region on the side, facing away from the corresponding base substrate, of the pixel circuit film layer; and

forming a second encapsulation layer exposing the opening region on the side, facing away from the corresponding pixel circuit film layer, of each base substrate.

In some embodiments, the first encapsulation layers and the second encapsulation layers include elastic materials. In some embodiments, the elastic materials may be coated by a knife-coating or liquid self-leveling process to form the first encapsulation layers and the second encapsulation layers respectively, and then when the temperature is lower than 100° C., the elastic materials are heated and dried and cured. In some embodiments, the heating and drying and curing processes of the deformable structure, the first protective layers and the second protective layers may be performed in the same process flow.

In some embodiments, when the display panel includes the first electrode layers and the second electrode layers, forming the first protective layers and the second protective layers may specifically include the step of coating with organic films or inorganic films.

An embodiment of the disclosure provides a display apparatus, and the display apparatus includes the display panel provided by the embodiment of the disclosure.

The display apparatus provided by the embodiment of the disclosure is: any product or component with a display function, such as a mobile phone, a tablet computer, a television, a display, a notebook computer, a digital photo frame, a navigator and a wearable product. Other essential components of the display apparatus will be apparent to those ordinarily skilled in the art and are not described in detail herein, nor should they be construed as limiting the disclosure. The display apparatus can be implemented by referring to the embodiment of the display panel, which is not repeated here.

To sum up, in the display panel, the manufacturing method of the display panel, and the display apparatus provided by the embodiments of the disclosure, the opening regions are provided with the deformable components filling the first via holes, and the deformable components include the elastic materials, so that the edges of the film layers run through by the first via holes are covered by the elastic materials, so as not to crack during the stretching process, thereby improving the stretch strength and stretch deformation of the display panel, and improving the stretch performance of the display panel.

It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosure without departing from the spirit or scope of the disclosure. Hence, if these modifications and variations of the disclosure fall within the scope of the claims and their equivalents in the disclosure, then it is intended that the disclosure includes these modifications and variations.