Array substrate and method of manufacturing the same, display panel and method of manufacturing the same, and display device

The invention discloses an array substrate, a display panel and methods of manufacturing the same, and a display device. The array substrate comprises: a pixel region and a wiring region located outside the wiring region; a gate line and a data line each arranged within both the pixel and wiring regions; a passivation layer arranged to cover the gate and data lines and provided therein with trenches respectively exposing and being wider than the gate and data lines within the wiring region; first and second signal line partially arranged within the trenches respectively and contacting exposed portions of the gate and data lines to transmit signals to the gate and gate lines respectively, the first and second signal line each having widths equal to those of the trenches respectively. With the invention, good electrical connections between the signal line and the gate and data lines are enabled.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of the Chinese Patent Application No. 201510345201.X filed on Jun. 19, 2015 in the State Intellectual Property Office of China, the whole disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

Field of the Invention

Embodiments of the present disclosure generally relate to the field of display technologies, and particularly, to an array substrate and a method of manufacturing the same, a display panel and a method of manufacturing the same, and a display device.

Description of the Related Art

Generally, a signal line is connected onto an array substrate in the following way of: forming a via hole in an insulation layer covering a metal lines (for example, a gate line or a data line) extending from a display region or a pixel region, such that a contact portion of the metal line is exposed, then connecting the signal line (for example, ITO) with the contact portion, such that a signal is transmitted through the signal line to the metal line of the array substrate exposed from the via hole in a wiring region, and then transmitted to the display region to form a display image.

The insulation layer covering the metal line is generally made of a non-metal material, and the via hole in the non-metal material has a depth of about 4,000˜10,000 angstroms. Breakage in the signal line will easily occur at an edge of the hole when the via hole has a larger depth. As shown inFIG. 1, a signal line is connected to a data line through a via hole in a passivation layer, and breakage will easily occur at portions indicated by the arrows; as shown inFIG. 2, a signal line is connected to a gate line through a via hole in a passivation layer and a via hole in a gate insulation layer, and breakage will easily occur at locations indicated by the arrows, which may lead to a failure in signal transmission from the signal line to the gate line and the data line, causing abnormal lighting of the pixel region. In addition, since the via hole is formed smaller at a connection between the signal line and the gate line or the data line, it is difficult for moisture generated in cutting process to completely volatilize, and oxidation of metals and electrical corrosion will easily occur under a certain temperature in the production line.

SUMMARY

At least one technique problem to be solved by the present disclosure is how to avoid breakage at connection between signal lines and gate lines and data lines so as to ensure a good electrical connection between the signal lines and the gate lines and data lines.

According to one aspect of the present disclosure,

there is provided an array substrate, comprising:

a pixel region and a wiring region, the pixel region being arranged inside the wiring region;

a gate line arranged within the pixel region and the wiring region and comprising a first portion extending over a first length within the wiring region;

a data line arranged within the pixel region and the wiring region and comprising a second portion extending over a second length within the wiring region;

a passivation layer provided within the pixel region and the wiring region and covering the gate line and the data line, a portion of the passivation layer within the wiring region being provided therein with a first trench, from which at least the first portion of the gate line is exposed and which has a width larger than a width of the first portion of the gate line, and/or a portion of the passivation layer within the wiring region being provided therein with a second trench, from which at least the second portion of the data line is exposed and which has a width larger than a width of the second portion of the data line;

a first signal line partially arranged within the first trench, and covering and contacting the portion of the gate line exposed from first trench so as to transmit a first signal to the gate line, a portion of the first signal line arranged within the first trench having a width equal to the width of the first trench; and

a second signal line, partially arranged within the second trench, and covering and contacting the portion of the data line exposed from second trench so as to transmit a second signal to the data line, a portion of the second signal line arranged within the second trench having a width equal to the width of the second trench.

Preferably, an end of the portion of the gate line extending into the wiring region and/or an end of the portion of the data line extending into the wiring region is located inside an outer edge of the wiring region.

Preferably, the first signal line completely covers and directly contacts the first portion of a corresponding gate line within the wiring region, and is electrically insulated from adjacent gate lines; and/or

the second signal line completely covers and directly contacts the second portion of a corresponding data line within the wiring region, and is electrically insulated from adjacent data lines.

Preferably, the array substrate further comprises:

a base substrate, on which the gate line is arranged; and

a gate insulation layer arranged on the gate line, wherein the data line is arranged on the gate insulation layer.

Preferably, the sum of a thickness of the gate line and a thickness of the first signal line is equal to the sum of a thickness of the passivation layer and a thickness of the gate insulation layer, and/or

the sum of a thickness of the data line and the thickness of the second signal line is equal to the thickness of the passivation layer.

According to another aspect of the present disclosure, there is further provided a display panel, comprising the array substrate as described above, and further comprising:

a color filter substrate assembled together with the array substrate,

wherein a region between a boundary of the color filter substrate and a boundary of the array substrate is the wiring region.

Preferably, the array substrate further comprises:

a reserved region arranged inside the wiring region and outside the pixel region,

wherein the reserved region is located between the boundary of the color filter substrate and a boundary of the pixel region.

Preferably, a portion of the first trench extends into the reserved region and has an end located outside the pixel region, and/or a portion of the second trench extends into the reserved region and has an end located outside the pixel region.

According to a further aspect of the present disclosure, there is provided a display device comprising the display panel as described above.

According to a still further aspect of the present disclosure, there is provided method of manufacturing an array substrate, the array substrate comprising a pixel region and a wiring region located outside the pixel region, the method comprising:

forming a gate line and a data line within the pixel region and the wiring region, wherein the gate line comprises a first portion extending over a first length within the wiring region, and the data line comprises a second portion extending over a second length within the wiring region;

forming a passivation layer within the pixel region and the wiring region to cover the gate line and the data line;

etching the passivation layer to form a first trench in the passivation layer, at least the first portion of the gate line being exposed from the first trench and the first trench having a width larger than a width of the first portion of the gate line, and/or to form a second trench in the passivation layer, at least the second portion of the data line being exposed from the second trench and the second trench having a width larger than a width of the second portion of the data line;

forming a first signal line, such that the first signal line is partially located within the first trench, and covers and contacts the first portion of the gate line so as to transmit a first signal to the gate line, a portion of the first signal line located within the first trench having a width equal to the width of the first trench;

forming a second signal line, such that the first signal line is partially located within the second trench, and covers and contacts the second portion of the data line so as to transmit a second signal to the data line, a portion of the second signal line located within the second trench having a width equal to the width of the second trench.

Preferably, forming a gate line and a data line comprises:

forming the gate line on a base substrate;

forming a gate insulation layer on the gate line; and

forming the data line on the gate insulation layer.

According to a still another aspect of the present disclosure, there is provided a method of manufacturing a display panel, comprising the method of manufacturing the array substrate as described above, and further comprising:

assembling the color filter substrate to the formed array substrate;

cutting the assembled substrates such that a boundary of the color filter substrate is spaced apart from a boundary of the array substrate by a first distance and that the wiring region is formed between the boundary of the color filter substrate and the boundary of the array substrate.

Preferably, cutting the assembled substrates further comprises: spacing the boundary of the color filter substrate apart from a boundary of the pixel region by a second distance such that a reserved region is formed between the boundary of the color filter substrate and the boundary of the pixel region.

Preferably, etching the passivation layer further comprises:

forming the first trench in the passivation layer to expose portions of the gate line located within the wiring region and the reserved region, the first trench extending through a third length within the reserved region without extending into the pixel region; and/or

forming the second trench in the passivation layer to expose portions of the data line located within the wiring region and the reserved region, the second trench extending through a fourth length within the reserved region without extending into the pixel region.

With the above technique solutions, trenches are provided in the passivation layer over the gate line and the data line, such that the first signal line completely covers the portion of the gate line within the wiring region, and the second signal line completely covers the portion of the data line within the wiring region, thereby it can ensure a good electrical connection between the first signal line and the gate line, and a good electrical connection between the second signal line and the data line, and can avoid unsatisfactory signal transmission due to breakage of the first signal line at its connection with the gate line or breakage of the second signal line at its connection with the data line.

LIST OF REFERENCE NUMERALS

DETAINED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

In order to make clearer understanding of the above objects, features and advantages of the present disclosure, the present invention will be described hereinafter in detail with reference to exemplary embodiments and attached drawings. It is noted that in case of no conflict, the embodiments of the present disclosure and features thereof may be combined.

In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, the present invention may be embodied in many different forms and should not be construed as being limited to the embodiment set forth herein; rather, these embodiments are provided so that the present invention will be thorough and complete, and will fully convey the concept of the disclosure to those skilled in the art.

An array substrate according to an embodiment of the present disclosure, as shown inFIG. 3, comprises: a pixel region10(that is, a region surrounded by dashed lines) and a wiring region20arranged outside the pixel region10;

a gate line1arranged within the pixel region10and the wiring region20and comprising a first portion located within the wiring region20, the first portion extending over a first length within the wiring region20;

a data line2arranged within the pixel region10and the wiring region20and comprising a second portion located within the wiring region20, the second portion extending over a second length within the wiring region20;

a passivation layer3(seeFIGS. 4.6and7) provided within the pixel region10and the wiring region20and covering the gate line1and the data line2, a portion of the passivation layer3within the wiring region20being provided therein with a first trench, from which at least the first portion of the gate line1is exposed and which has a width larger than a width of the first portion of the gate line1, and/or a portion of the passivation layer3within the wiring region being provided therein with a second trench, from which at least the second portion of the data line2is exposed and which has a width larger than a width of the second portion of the data line2;

a first signal line4partially arranged within the first trench and covering and contacting the portion of the gate line1exposed from first trench so as to transmit a first signal to the gate line1, as shown inFIG. 4, a portion of the first signal line4arranged within the first trench having a width equal to the width of the first trench; and

a second signal line5partially arranged within the second trench and covering and contacting the portion of the data line exposed from second trench so as to transmit a second signal to the data line2, as shown inFIG. 6, a portion of the second signal line5arranged within the second trench having a width equal to the width of the second trench.

Since the width of the first signal line4is equal to that of the first trench, and the width of the first trench is larger than that of the first portion of the gate line1, the width of the first signal line4is larger than that of the first portion of the gate line1, such that the first signal line4may completely cover the portion of the gate line1within the wiring region20, and correspondingly, the second signal line5may completely cover the portion of the data line2within the wiring region20, such that the signal lines have large contact areas with the gate line1and the data line2within the wiring region, and no bad electrical connection will occur due to breakage of connection in some regions. Thus, good electrical connections can be established between the signal lines and the gate line1and the data line2, such that signals from the signal lines can be successfully transmitted to the gate line1and the data line2so as to control the pixel region20.

Further, since the width of the first trench is larger than that of the first portion of the gate line1, and the width of the second trench is larger than that of the second portion of the data line2, cross sectional areas of the trenches are much larger than those of via holes in the passivation layer3in prior arts. Thus, it can ensure a complete volatilization of the moisture generated in cutting process, and oxidation or electrical corrosion of the signal line, the gate line1or the data line2in the trenches can be avoided, so that good electrical performance of product can be ensured. Further, since the first signal line4completely covers the portion of the gate line1within the wiring region20and the width of the first signal line4is larger than that of the portion of the gate line1within the wiring region20, the first signal line4can cover a gap between the portion of the gate line1within the wiring region20and a gate insulation layer7, as shown inFIG. 4, so as to prevent corrosion of the gate line1caused by penetration of oxygen or moisture into the gap in subsequent processes. Similarly, the second signal line5can completely cover a gap between the portion of the data line2within the wiring region20and the passivation layer3, as shown inFIG. 6, so as to prevent corrosion of the data line2caused by penetration of oxygen or moisture into the gap in subsequent processes.

As shown inFIGS. 3.5and7, preferably, an end of the portion of the gate line1extending into the wiring region20and an end of the portion of the data line2extending into the wiring region20are located within the wiring region20, that is, the ends are located inside an outer edge of the wiring region20or does not go beyond the outer edge of the wiring region20; in other words, the gate line1and the data line2are ended in the wiring region20.

It is known that each array substrate is obtained by cutting a mother board, and a cutting line, along which the mother board is cut into respective array substrates, is located at the outer edge of the wiring region20. Thus, if the gate line1and the data line2are arranged at or near the outer edge of the wiring region20, a cutting operation will generate uneven portions (for example, burrs) at ends of the gate line1and the data line2being cut when cutting the mother board along the cutting line, which results in a non-uniform distribution of resistance of the gate line1and the data line2and unevenness at a connection portion between the first signal line4and the gate line1and a connection portion between the second signal line5and the data line2, such that poor contact may occur easily.

In embodiments of the present disclosure, with the ends of the portions of the gate line1and the data line2extending into the wiring region20being located within the wiring region20, it can be ensured that the gate line1and the data line2of the array substrate will not be cut when cutting and dividing the mother board, and that surfaces of the gate line1and the data line2within the wiring region20are even, thereby good electrical connections between the first signal line4and the gate line1and between the second signal line5and the data line2can be achieved.

It is noted that, the lengths at which the gate line1and the data line2extend within the wiring region are equal to or different from each other, and may be particularly set according to requirements of connection.

Preferably, the first signal line4completely covers and directly contacts the portion of the gate line1within the wiring region, and is electrically insulated from adjacent gate lines; and/or the second signal line5completely covers and directly contacts the portion of the data line2within the wiring region, and is electrically insulated from adjacent data lines.

Preferably, the array substrate according to embodiments of the present disclosure further comprises: a base substrate6, on which the gate line1is arranged; and a gate insulation layer7arranged on the gate line1, wherein the data line2is arranged on the gate insulation layer7.

Preferably, the sum of a thickness of the gate line1and a thickness of the first signal line4is equal to the sum of a thickness of the passivation layer3and a thickness of the gate insulation layer7, and/or

the sum of a thickness of the data line2and a thickness of the second signal line5is equal to the thickness of the passivation layer3.

With such a configuration, it can be ensured that upper surfaces of the first signal line4and the second signal line5are located within the same plane as an upper surface of the passivation layer3, so as to provide a basis of evenness for subsequent processes.

Embodiments of the present disclosure further provide a display panel, comprising:

the array substrate according to any one of the above embodiments; and

a color filter substrate assembled together with the array substrate,

wherein a region between a boundary301of the color filter substrate and a boundary201of the array substrate is the wiring region20, as shown inFIG. 8.

Preferably, the array substrate further comprises a reserved region30arranged inside the wiring region20and outside the pixel region10, as shown inFIG. 8, wherein the reserved region30is located between the boundary301of the color filter substrate and a boundary101of the pixel region10.

After assembling the color filter substrate to the array substrate, it is required to cut edges of the color filter substrate to form the wiring region20in portions of the array substrate outside the color filter substrate, so as to be assembled and connected with other modules (for example, a printed circuit board).

With the reserved region30being provided between the pixel region10and the wiring region20, damage to the pixel region10can be prevented when cutting the color filter substrate and the resulted display panel has a good display effect.

Preferably, a portion of the first trench extends into the reserved region30and does not extend into the pixel region10, and/or a portion of the second trench extends into the reserved region30and does not extend into outside the pixel region10.

Since the first signal line4is arranged within the first trench and can cover the portion of the gate line1within reserved region30and the second signal line5is arranged within the second trench and can cover the portion of the data line2within reserved region30, in case of an overcutting during cutting the color filter substrate, the rigid first signal line4and/or second signal line5may be firstly partially damaged, but the gate line1and the data line2will not be firstly damaged. The first signal line4and the gate line1contact the second signal line5and the data line2at the cutting line of the color filter substrate and at other positions such as the wiring region20, thus the electrical connection between the first signal line4and the gate line1and the electrical connection between the second signal line5and data line will not be affected when the first signal line4and the second signal line5are cut at the cutting line of the color filter substrate. Thereby, damages to the gate line1under the first signal line4and to the data line2under the second signal line5can be reduced when cutting the color filter substrate, so that good signal transmission on the gate line1and the data line2can be ensured.

Embodiments of the present disclosure further provide a display device, comprising the display panel according to any one of the above described embodiments.

It is noted that, the display device in the embodiments of the present disclosure may be an electronic paper, a mobile phone, a tablet computer, a TV set, a notebook PC, a digital picture frame, a navigator or any other products or components having a display function.

Embodiments of the present disclosure further provide a method of manufacturing an array substrate, as shown inFIG. 9, the array substrate comprises a pixel region10and a wiring region20located outside the pixel region, and the method comprises the following steps of:

S1: forming a gate line1and a data line2within the pixel region10and the wiring region20, wherein the gate line1comprises a first portion located within the wiring region20and extending over a first length within the wiring region20, and the data line2comprises a second portion located within the wiring region20and extending over a second length within the wiring region20;

S2: forming a passivation layer3within the pixel region10and the wiring region20to cover the gate line1and the data line2;

S3: etching the passivation layer3to form a first trench in a portion of the passivation layer3within the wiring region20, the first portion of the gate line1being exposed from the first trench and the first trench having a width larger than a width of the first portion of the gate line1, and/or to form a second trench in a portion of the passivation layer3within the wiring region20, the second portion of the data line2being exposed from the second trench and the second trench having a width larger than a width of the second portion of the data line2; and

S4: forming a first signal line4such that the first signal line4is partially located within the first trench and covers and contacts the first portion of the gate line1to transmit a first signal to the gate line1, a width of a portion of the first signal line4located within the first trench being equal to the width of the first trench, and forming a second signal line5such that the second signal line is partially located within the second trench and covers and contacts the second portion of the data line2to transmit a second signal to the data line2, a width of a portion of the second signal line located within the second trench being equal to the width of the second trench.

Preferably, the step of forming the gate line1and the data line2comprises:

forming the gate line1on a base substrate6;

forming a gate insulation layer7on the gate line1; and

forming the data line2on the gate insulation layer7.

Embodiments of the present disclosure further provide a method of manufacturing a display panel, comprising the method of manufacturing the array substrate as described above, and further comprising:

assembling the color filter substrate to the array substrate having been formed;

cutting the assembled substrates such that a boundary of the color filter substrate is spaced apart from a boundary of the array substrate by a first distance, wherein a region between the boundary of the color filter substrate and the boundary of the array substrate is the wiring region20.

Preferably, cutting the assembled substrates further comprises spacing the boundary of the color filter substrate apart from a boundary of the pixel region10by a second distance, wherein a region between the boundary of the color filter substrate and the boundary of the pixel region10is the reserved region30.

Preferably, etching the passivation layer3further comprises: forming the first trench in the passivation layer3to expose a portion of the gate line1located within the wiring region20and the reserved region30, the first trench extending over a third length within the reserved region30without extending into the pixel region10; and/or forming the second trench in the passivation layer3to expose a portion of the data line2located within the wiring region20and the reserved region30, the second trench extending over a fourth length within the reserved region30and not extending into the pixel region10.

In an example, the forming steps in the above manufacturing processes may include, for example, film forming processes such as deposition, sputtering and the like, and patterning processes such as etching and the like.

It is noted that, in the drawings, sizes of layers and regions may be magnified for a clear illustration. Further, it will be understood that, when an element or layer is located “on” another element or layer, it may be directly on the another element or layer, or there may be an intermediate element or layer therebetween. Similarly, it will also be understood that, when an element or layer is located “under” another element or layer, it may be directly under the another element or layer, or there may be one or more intermediate element or layer therebetween. In addition, it will be appreciated that, when a layer or element is located “between” two layers or elements, it may be the only layer or element between the two layers or elements, or there may be more than one or more other intermediate elements or layers. Similar reference numerals indicate similar elements throughout the document.

In the present disclosure, terms “first”, “second”, “third” and the like are only intended for description purpose, but could not be understood as indicating or implying relative importance. Term “a plurality of” refers to two or more, unless otherwise expressly defined.

The above described contents are only preferred embodiments of the present disclosure, and are not intended to limit the present disclosure. Various modification and changes may be made to the present disclosure by those skilled in the art. All changes, alternatives or modifications which are made within the principles and spirit of the present disclosure should fall within the scopes of the present invention.