Package structure, flexible display screen, and method for manufacturing package structure

A package structure, a flexible display screen, and a method for manufacturing the package structure are provided. The package structure is used for packaging and being bonded on a display panel. The package structure includes a first inorganic layer, the first inorganic layer includes a number of first inorganic elements that are discontinuously arranged on the display panel and a number of second inorganic elements each of which is connected between two adjacent first inorganic elements. By providing the second inorganic elements between the discontinuously arranged first inorganic elements, so that the first inorganic elements and the second inorganic elements are arranged alternately and prevent each other from absorbing water/oxygen, thereby improving the water/oxygen barrier performance of the package structure, that is, the package performance of the package structure is improved.

RELATED APPLICATIONS

The present application is a National Phase of International Application Number PCT/CN2015/100162, filed Dec. 31, 2015.

TECHNICAL FIELD

The present disclosure relates to the field of flexible display screens, and more particularly relates to a package structure, a flexible display screen, and a method for manufacturing the package structure.

BACKGROUND

At present, with widely use of flexible display screens, most flexible display screen encapsulate an organic electroluminescence layer (OLED) by using a package structure, to prevent the organic electroluminescence layer from absorbing water/oxygen and fail. However, the present package structures have single structures, most of the package structures are made by alternately stacking organic layers and inorganic layers, which leads to the present package structure easily absorbing too much water/oxygen in a humid environment, resulting in detachment of the organic layer and inorganic layer of the package structures, which affects the performance of the package structure.

SUMMARY

The object of the present disclosure is to provide a package structure with a stable structure, a flexible display screen, and a method for manufacturing the package structure.

In order to solve the above problems, the present disclosure provides a package structure, which is configured for packaging and being bonded to a display panel. The package structure includes a first inorganic layer, and the first inorganic layer includes a number of first inorganic elements that are discontinuously arranged on the display panel and a number of second inorganic elements each of which is connected between two adjacent first inorganic elements.

The present disclosure further provides a flexible display screen. The flexible display screen includes a package structure and a display panel. The first inorganic layer includes a number of first inorganic elements that are discontinuously arranged on the display panel and a number of second inorganic elements each of which is connected between two adjacent first inorganic elements.

The present disclosure further provides a method for manufacturing a package structure. The method includes: forming a first inorganic layer, wherein the first inorganic layer includes a number of first inorganic elements that are discontinuously arranged on the display panel and a number of second inorganic elements each of which is connected between two adjacent first inorganic elements.

In the present disclosure, the package structure, the flexible display screen, and the method for manufacturing the package structure stack a first inorganic layer on a display panel, the first inorganic layer includes a number of first inorganic elements that are discontinuously connected to each other and a number of second inorganic elements each of which is connected between two adjacent first inorganic elements. By alternately arranging the second inorganic elements and the first inorganic elements, so that the first inorganic elements and the second inorganic elements can prevent each other from absorbing water/oxygen, and can prevent water/oxygen from diffusing. Therefore, the water/oxygen barrier performance of the package structure is improved, that is, the package performance of the package structure is improved.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS

The technical solutions of embodiments of the present disclosure will be described clearly and completely in combination with the accompanying drawings of the embodiments of the present disclosure.

Referring toFIGS. 1 and 2, the present disclosure provides a package structure100, which is bonded to a display panel101. The display panel101includes a number of light-emitting units102arranged in an array and a number of pixel defining units103each of which is connected between two adjacent light-emitting units102. The package structure100includes a first inorganic layer10. The first inorganic layer10includes a number of first inorganic elements11and a number of second inorganic elements12each of which is connected between two adjacent first inorganic elements11. The first inorganic elements11are arranged in an array. The first inorganic elements11are bonded to and cover the light-emitting units102, and the second inorganic elements12are bonded to and cover the pixel defining units103. It should be understood that, the display panel101may be an organic electroluminescence layer (OLED), or a liquid crystal display light-emitting layer (LCD). In the embodiment, taking the display panel101as an organic electroluminescence layer, for example. The package structure100encapsulates the display panel101, to prevent the display panel101from absorbing water/oxygen, and further to prevent the display panel101from display failure.

By stacking a the first inorganic layer10on the display panel101, and the first inorganic layer10including a number of first inorganic elements11arranged in an array and a number of second inorganic elements12each of which is connected between two adjacent first inorganic elements11, so that the first inorganic elements11correspond to the light-emitting units102. By connecting the second inorganic element12between two adjacent first inorganic elements11, so that the first inorganic elements11are discontinuously connected to each other, and the first inorganic elements11and the second inorganic elements12are arranged alternately. The materials of the first inorganic elements11are different from the materials of the second inorganic elements12, and the first inorganic elements11and the second inorganic elements12can prevent each other from absorbing water/oxygen, and can prevent water/oxygen from diffusing. Therefore, the water/oxygen barrier performance of the first inorganic layer10is improved, that is, the package performance of the package structure is improved.

In the embodiment, the first inorganic elements11are arranged in a rectangular array, and the first inorganic elements11are arranged along two perpendicular directions. The first inorganic elements11are made of inorganic materials, and the first inorganic elements11have good water/oxygen barrier performance and light translucent. Moreover, the physical stability and chemical stability of the first inorganic element11can effectively protect the display panel101, cut off water/oxygen erosion, and prevent the display panel101from degradation. Each first inorganic element11has a rectangular plate shape, and each first inorganic element11has a transparent property, so each first inorganic element11can transmit the light emitted from the light-emitting unit102, without affecting the display performance of the display panel101. Each first inorganic element11is independent from each other, which can improve water/oxygen barrier performance.

In the embodiment, the second inorganic elements12have a grid shape, and are formed by metal wires that are arranged in a crisscross pattern. The second inorganic elements12separate the first inorganic elements11, and are fixedly connected to the first inorganic elements11. The second inorganic elements12have metal ductility. With waterproof and anti-oxidation properties of metal, the water/oxygen barrier performance of the second inorganic elements12can be improved. The second inorganic elements12have stable performance, so that the structures between the second inorganic elements12and the pixel defining units103are stable, thereby making the structures between the first inorganic layer10and the display panel101be stable. The second inorganic elements12are stacked on the pixel defining units103, and the second inorganic elements12and the light-emitting units102are staggered, so that the second inorganic elements12may have no effect to the display performance of the display panel101, that is, the good light translucent performance of the package structure can be ensured.

The package structure100further includes a first organic layer20, the first organic layer20is bonded to one side of the first inorganic layer10which is far away from the display panel101, and completely covers the first inorganic layer10. The first organic layer20is made of organic materials. In the embodiment, by stacking the first organic layer20on the first inorganic layer10, thereby flattening the first inorganic layer10, so as to flatten the package structure and improve the service performance of the package structure100, which facilitates the application of the package structure100and the display panel101to mobile device. In addition, the first organic layer20completely covers the first inorganic layer10, that is, the first organic layer20completely covers the first inorganic elements11and the second inorganic elements12, so as to make the structure of the package structure100compact, and further to improve the stability of the package structure100.

The package structure100further includes a second inorganic layer30and a second organic layer40. The second inorganic layer30is stacked on one side of the first organic layer20which is far away from the first inorganic layer10. The second inorganic layer30includes a number of third inorganic elements31and a number of fourth inorganic elements32each of which is connected between two adjacent third inorganic elements31. The third inorganic elements31are arranged in an array. Each of the third inorganic elements31covers a first inorganic element11, and each of the fourth inorganic elements32covers a second inorganic element12. The second organic layer40is stacked on one side of the second inorganic layer30which is far away from the first organic layer20, and completely covers the second inorganic layer30.

In the embodiment, the arrangement of the second inorganic layer30is the same as the arrangement of the first inorganic layer10, that is, the materials of the third inorganic elements31may be the same as the materials of the first inorganic elements11, and the materials of the fourth inorganic elements32may be the same as the materials of the second inorganic elements12. By stacking the second inorganic layer30on the first organic layer20, and by further utilizing the bending resistant properties and water/oxygen barrier properties of the second inorganic layer30, so that the packaging effect of the package structure100can be improved. The materials of the second organic layer40may be the same as the materials of the first organic layer20. The second organic layer40flattens the second inorganic layer30, and improves the flatness of the package structure100, and enhances the structural stability of the package structure100.

Further, the thickness of the second inorganic layer30is less than the thickness of the first inorganic layer10, so as to effectively reduce the thickness of the package structure100, so that the package structure100can be applied to slim mobile device, which can reduce the thickness of the mobile device, and increase application performance of the package structure100.

Further, there may be multi-layer second inorganic layers30and multi-layer second organic layers40, and the multi-layer second inorganic layers30and the multi-layer second organic layers40are alternately stacked.

In the embodiment, a second organic layer40is stacked on one side of each of the second inorganic layers30which is far away from the first inorganic layer10by utilizing the alternately stacked multiple second inorganic layer30and multiple second organic layer40to increase the water/oxygen barrier channel of the package structure100, thereby the packaging performance of the package structure100can be improved.

The package structure100further includes a protective layer50. The protective layer50is bonded to one side of the outermost second organic layer40which is far away from the second inorganic layer30, and completely covers the first inorganic layer10. In the embodiment, the protective layer50is deposited on the second organic layer40. The protective layer50is configured to protect the first inorganic layer10, the first organic layer20, the second inorganic layer30and the second organic layer40, and the protective layer50has good waterproof and anti-corrosion properties, so as to increase the service life of the package structure100. The protective layer50is further configured to protect the second inorganic elements12and the fourth inorganic elements32from oxidizing or corrupting, so as to ensure that the package structure100has good water/oxygen barrier properties and good bending resistant properties. The protective layer50may be formed by thermal evaporation of magnesium fluoride, so that the protective layer50may protect the second inorganic elements12and the fourth inorganic elements32. The protective layer50may also be formed by chemical vapor deposition, physical vapor deposition, or vacuum evaporation. The protective layer50has good anti-corrosion and waterproof properties, so that the protective layer50has better protective performance. Further, the materials of the first inorganic element11is selected form a group consisting of aluminum oxide, tin oxide, zinc oxide, titanium oxide, zirconium oxide, silicon nitride, silicon oxide nitride, and any combination thereof. The materials of the second inorganic element12may be selected form any one metal materials of silver, copper, and aluminum. By utilizing the metal oxide characteristics of the second inorganic element12, so that the first inorganic element11and the second inorganic element12may be integrally molded, thereby making the structure between the first inorganic element11and the second inorganic element12stable. Moreover, the first inorganic element11has good flexibility under the good light translucent performance, so as to meet the package requirement of the package structure100. As the second inorganic elements12are made of metal materials, the second inorganic elements12have better water/oxygen barrier properties and good bending resistant properties, so as to improve the durability of the package structure100. As the second inorganic elements12are made of materials with high thermal conductivity such as silver, copper, or aluminum, the second inorganic elements12can effectively conduct heat for the display panel101, that is, effectively dissipate the heat generated by the light-emitting unit102, so as to improve the thermal performance of the package structure, and further meet the multi-functional requirements of the package structure100.

Further, the materials of the first organic layer20is selected form a group consisting of polyethylene terephthalate, polyimide, epoxy, polyethylene, polypropylene, and any combination thereof The first organic layer20is made of organic compound materials, so the first organic layer20can be easily molded, and has a stable structure, and the durability is improved. The first organic layer20protects the first inorganic layer10, and blocks the connection channel between the first inorganic element11and the second inorganic element12, to prevent the first inorganic element11and the second inorganic element12from detaching from each other, and further enhance the stability of the package structure100. The first organic layer20effectively satisfies the slim requirement of the package structure100, and facilitates the application of the package structure100to any device.

The present disclosure further provides a flexible display screen200. The flexible display screen200includes the package structure100, a flexible back plate210and the display panel101. The display panel101is stacked on the flexible back plate210. The display panel101includes a number of light-emitting units102and a number of pixel defining units103each of which is connected between two adjacent light-emitting units102, and the light-emitting units102are arranged in an array. The package structure100is bonded to the display panel101. The first inorganic elements11are bonded to and cover the light-emitting units102, and the second inorganic elements12are bonded to and cover the pixel defining units103.

In the embodiment, the flexible back plate210is a rectangular plate. The flexible back plate210may be a thin film transistor (TFT). Driving electrodes are arranged in the flexible back plate210, to drive the organic electroluminescence layer (OLED), namely the display panel101to emit light. The flexible back plate210can be bent freely, and includes a first outer surface210aand a first inner surface210bthat are opposite to each other. The display panel101is fixed on the first inner surface210b.The materials of the flexible back plate210is selected from a group consisting of polyethylene naphthalate, polyethylene terephthalate, or polyimide resin.

In the embodiment, the display panel101is an OLED (Organic Light-Emitting Diode). Specifically, the light-emitting unit102is composed of three primary-colors sub-pixels of RGB, and the pixel defining unit103controls the combination of the three primary-colors sub-pixels in the light-emitting unit102to emit light, so that the light-emitting units102exhibit different colors. The pixel defining unit103does not emit light. In another embodiment, the display panel101may also be a liquid crystal display light-emitting layer (LCD).

Specifically, the display panel101further includes a number of insulating films220, a passivation layer230, a number of electrode assemblies240, and a number of driving assemblies250. The insulating films220and the passivation layer230are stacked on the flexible back plate210in order. The light-emitting units102and the pixel defining units103are both stacked on the passivation layer230. Each electrode assembly240is bonded to a light-emitting unit102, and electrically connected to a pixel defining unit103, to input electrical signals to the corresponding light-emitting unit102. Each driving assemblies250is embedded in the insulating films220and opposite to a pixel defining units103. The driving component250is electrically connected to a electrode assembly240and the corresponding pixel defining unit103for driving the corresponding light-emitting unit102to emit light. The insulating films220provide the driving assemblies250with an insulating environment, so that the driving assemblies250are able to receive electrical signals. The driving assemblies250receive the driving electrical signals, and the driving electrode assemblies240send voltage changes to the corresponding light-emitting units102, to drive the corresponding light-emitting units102to emit light. The pixel defining unit103receives scan electrical signals, to control different RGB sub-pixels in the corresponding light-emitting unit102to emit light, such that the corresponding light-emitting unit102exhibits a color change.

More specifically, each electrode assembly240includes an anode241and a cathode242. The anode241is fixed between a corresponding light-emitting unit102and the passivation layer230, and is arranged opposite to the corresponding light-emitting unit102. The anode241is electrically connected to a corresponding driving assembly250. The cathode242is fixed between a corresponding light-emitting unit102and the package structure100, and is arranged opposite to the anode241. The cathode242is electrically connected to a corresponding driving assembly250. Each driving assembly250includes an active wire251, a gate252, a source253and a drain254. The active wire251is arranged opposite to a corresponding pixel definition unit103, the source253is electrically connected between the active wire251and the anode241, the drain254is electrically connected between the cathode242and the active wire251, and the gate252is electrically connected to the source253and the drain254. The active wire251receives electrical signals and controls the anode241and the cathode242to apply voltage changes to the corresponding light-emitting unit102via the gate252, the source253, and the drain254. As both of the driving component250and the pixel defining unit103receive the electrical signals, a large amount of heat is easily generated. As neither the pixel defining unit103nor the driving component250emits light, and by utilizing the second inorganic elements12of the package structure100to cover the corresponding driving components250and the corresponding pixel defining units103, on one hand, the good thermal conductivity of the second inorganic elements12can dissipate the heat generated by the pixel defining unit103and the driving assembly250, on the other hand, the second inorganic elements12and the light-emitting unit102are staggered, so as to ensure good light transmittance of the package structure100. Therefore, the flexible display200has long service life and excellent performance.

The present disclosure further provides a method for manufacturing a package structure. The method for manufacturing the package structure provided by the embodiments of the present disclosure will be described in detail below in combination with the accompanyingFIGS. 3 to 5. It should be noted that, the method for manufacturing the package structure ofFIGS. 3 to 5, is configured to manufacture the structure of the embodiments illustrated inFIGS. 1 and 2of the present disclosure. For convenience of description, only parts related to the embodiments of the present disclosure are shown. For specific technical details that are not disclosed, reference is made to the embodiments illustrated inFIGS. 1 and 2of the present disclosure. The method for manufacturing the package structure is configured to manufacture a package structure100on a display panel101, and may include the follows.

S01, a first inorganic layer10is formed. The first inorganic layer10includes a number of first inorganic elements11arranged in an array and a number of second inorganic elements12each of which is connected between two adjacent first inorganic elements11. The first inorganic elements11are bonded to the corresponding light-emitting units102, and the second inorganic elements12are bonded to the corresponding pixel defining units103.

In the embodiment, the first inorganic layer10is formed by vapor deposition using a masks, and may specifically include the follows.

S101, a number of first inorganic elements11are formed using a first mask310in a grid shape.

As illustrated inFIGS. 6 and 8, the first mask310includes a number of first cover portions311in a ‘’#” shape and a number of first hollow regions312each of which is arranged among the adjacent first cover portions311. The first mask310is placed on the display panel101, with the first cover portions311covering the corresponding pixel defining units103, and the first hollow regions312overlapping the corresponding light-emitting units102, then the first inorganic elements11are deposited by a vacuum device in the first hollow regions312, so that the first inorganic elements10covers the corresponding light-emitting units102.

S102, a number of first metal stripes121extending along a horizontal direction are formed using a second mask320in a stripe shape. Each first metal stripe121is arranged between two adjacent first inorganic elements11arranged along a longitudinal direction.

As illustrated inFIGS. 7 and 8, the second mask320includes a number of second cover portions321extending along the horizontal direction and a number of second hollow regions322each of which is arranged between two adjacent second cover portions321. The second cover portions321are arranged side by side along the longitudinal direction, and the second hollow regions322are slots extending along the horizontal direction. The first mask310is removed from the display panel101, and the second mask320is placed on the display panel101, with the second cover portions321correspondingly covering the first inorganic elements11arranged along the horizontal direction, and the second hollow regions322overlapping the corresponding pixel defining units103arranged along the horizontal direction. Therefore, the first metal stripes121are deposited by a deposition device on the pixel defining units103arranged along the horizontal direction.

S103, a number of second metal stripes122extending along the longitudinal direction are formed using a third mask (not illustrated) in a stripe shape. Each second metal stripe122is arranged between two adjacent first inorganic elements11arranged along the horizontal direction. The second metal stripes122and the first metal stripes121constitute the second inorganic elements12.

The structure of the third mask is the same as the second mask320, except that the placing direction of the third mask on the display panel101is rotated by 90° relative to the second mask320. Specifically, after the second mask320is rotated by 90°, the second covering portions321correspondingly covers the first inorganic elements11arranged along the longitudinal direction, and the second hollow region322overlaps the corresponding pixel defining units103arranged along the longitudinal direction. Therefore, the second metal stripes122are deposited by the deposition device on the pixel defining units103arranged along the longitudinal direction.

S02, a first organic layer20is formed on the first inorganic layer10. The first organic layer is made of organic materials, and completely covers the first inorganic layer10.

The first organic layer20is formed by vacuum evaporation or inkjet printing, and may specifically include the follows.

S201, a layer of precursors (not illustrated) is inkjet printed or vacuum deposited on the first inorganic layer10.

The precursors may be raw materials of the first organic layer20. The precursors may be laid on the first inorganic layer10to form the first organic layer20by physical processing or chemical processing.

S202, the precursors are UV cured or thermally cured to form the first organic layer20.

The precursors are a light-sensitive materials or a heat-sensitive materials, so that the first organic layer20is firmly bonded to the first inorganic layer10.

S03, a second inorganic layer30is formed on one side of the first organic layer20which is far away from the first inorganic layer10. The second inorganic layer30includes a number of third inorganic elements31arranged in an array and a number of fourth inorganic elements32each of which is connected between two adjacent third inorganic elements31. Each of the third inorganic elements31corresponds to a first inorganic element11, and each of the fourth inorganic elements32corresponds to a second inorganic element12. The specific molding process of the second inorganic layer30and the specific molding process of the first inorganic layer10may be the same, which will not repeated herein, except that the thickness of the second inorganic layer30is less than the thickness of the first inorganic layer10.

S04, a second organic layer40is formed on one side of the second inorganic layer30which is far away from the first organic layer20. The second organic layer40completely covers the second inorganic layer30. The specific molding process of the second organic layer40and the specific molding process of the first organic layer20may be the same, which will not be repeated herein.

In the embodiment, the processes of step S04and step S05are repeated multiple times, and multi-layer second inorganic layers30and multi-layer second organic layers40alternately stacked are finally formed.

S05, a protective layer50is formed on one side of the second organic layer40which is far away from the second inorganic layer30. The protective layer50completely covers the first inorganic layer10.

In the present disclosure, the package structure, the flexible display screen, and the method for manufacturing the package structure stack a first inorganic layer on a display panel, the first inorganic layer includes a number of first inorganic elements that are discontinuously connected to each other and a number of second inorganic elements each of which is connected between two adjacent first inorganic elements. By alternately arranging the second inorganic elements and the first inorganic elements, so that the first inorganic elements and the second inorganic elements can prevent each other from absorbing water/oxygen, and can prevent water/oxygen from diffusing. Therefore, the water/oxygen barrier performance of the package structure is improved, that is, the package performance of the package structure is improved.

The above are the preferred embodiments of the present disclosure. It should be noted that those skilled in the art may still make various improvements and modifications without departing from the principle of the present disclosure, and such improvements and modifications are also considered to be within the scope of the present disclosure.