Patent ID: 12207525

DETAILED DESCRIPTION

In one embodiment, the present disclosure provides a display panel. Please refer toFIG.1toFIG.3.FIG.1is a first structural schematic view showing the display panel provided by the embodiment of the present disclosure.FIG.2is a first structural schematic plan view showing the display panel provided by the embodiment of the present disclosure.FIG.3is a second structural schematic view showing the display panel provided by the embodiment of the present disclosure. The display panel provided by the present embodiment of the present disclosure includes:an array substrate10;a display functional layer20disposed on the array substrate layer10;a first inorganic encapsulation layer30disposed on a side of the display functional layer20away from the array substrate layer10; anda composite barrier layer40disposed on a side of the first inorganic encapsulation layer30away from the display functional layer20, wherein the composite barrier layer40includes:a base41;a viscosity-reducing adhesive layer42disposed between the base41and the first inorganic encapsulation layer30;a second inorganic encapsulation layer43disposed between the viscosity-reducing adhesive layer42and the first inorganic layer30; andan organic adhesive layer44disposed between the second inorganic encapsulation layer43and the first inorganic encapsulation layer30.

Specifically, the base41is an organic base. Material of the base includes, but is not limited to, polyimide (PI) and polyethylene terephthalate (PET). The base is disposed on a surface of the display panel and covers an encapsulation layer of the display panel. The base is configured to protect the encapsulation layer of the display panel when the display panel is transported from a panel-manufacturing workshop to a module-manufacturing workshop.

The viscosity-reducing adhesive layer42is an organic adhesive layer. Viscosity of the viscosity-reducing adhesive layer42can be adjusted by a viscosity-reducing process. In a first state, i.e., before the viscosity-reducing process, the viscosity-reducing adhesive layer42is configured to attach the base41to the second inorganic encapsulation layer43. The viscosity of the viscosity-reducing adhesive layer42is greater than 500 gf/25 mm. In a second state, i.e., after the viscosity-reducing process, the viscosity of the viscosity-reducing adhesive layer42is reduced below 2 gf/25 mm, thereby removing the viscosity-reducing adhesive layer42from the second inorganic encapsulation layer43. The viscosity-reducing process can be adjusted according to different material of the viscosity-reducing adhesive layer42. When the material of the viscosity-reducing adhesive layer42includes an organic adhesive material whose viscosity is reduced during ultraviolet irradiation and an organic adhesive material whose viscosity is reduced when being heated, the viscosity-reducing adhesive process correspondingly includes an ultraviolet irradiation process and a heating process.

The organic adhesive layer44is an organic layer having viscosity, and is configured to attach the first inorganic encapsulation layer30to the second inorganic encapsulation layer43. The organic adhesive layer44is located between the first inorganic encapsulation layer30and the second inorganic encapsulation layer43. The organic adhesive layer44, the first inorganic encapsulation layer30, and the second inorganic encapsulation layer43together constitute a flexible encapsulation layer of the display panel, thereby making the display panel flat and releasing applied forces. As such, the viscosity of the organic adhesive layer is greater than 500 gf/25 mm, thereby ensuring that the first inorganic encapsulation layer30and the second inorganic encapsulation layer43can be attached to each other by the organic adhesive layer44in the first state and the second state. Preferably, the organic adhesive layer44is a pressure sensitive adhesive (PSA). Material of the organic adhesive layer includes, but is not limited to, vinyl, polyurethane, polyester, and vinyl acetate.

In one embodiment, as shown inFIG.1andFIG.2, the first inorganic encapsulation layer30covers all of the display functional layer20and part of the array substrate layer10, thereby encapsulating the display functional layer20. The organic adhesive layer44covers all of the first inorganic encapsulation layer30. The second inorganic encapsulation43covers the organic adhesive layer44. Preferably, a lateral wall of the second inorganic encapsulation layer43is aligned with a lateral wall of the organic adhesive layer44. Alternatively, the second inorganic encapsulation layer43covers an upper surface and a lateral surface of the organic adhesive layer44. The viscosity-reducing adhesive layer42covers all of the second inorganic encapsulation layer43, the lateral wall of the organic adhesive layer44, and part of the array substrate layer10.

A distance X1between a lateral wall of the first inorganic encapsulation layer30and a lateral wall of the display functional layer20is greater than 200 μm, thereby ensuring that the first inorganic encapsulation layer30can cover all of the display functional layer20. A distance X2between the lateral wall of the second inorganic encapsulation layer and the lateral wall of the first inorganic encapsulation layer is greater than 100 μm, thereby ensuring that the viscosity-reducing adhesive layer42can cover all of the first inorganic encapsulation layer30. A distance X3between a lateral wall of the viscosity-reducing adhesive layer42and the lateral wall of the second inorganic encapsulation layer is greater than 1 mm, thereby ensuring that the viscosity-reducing adhesive layer42can cover all of the encapsulation layer and enough area of the array substrate layer10. Therefore, the viscosity-reducing adhesive layer42and the array substrate layer10are prevented from being separated from each other.

Generally, the display functional layer20only has a few micrometers thickness. A thickness of the first inorganic encapsulation layer30ranges from 0.3 μm to 1 μm. A thickness of the second inorganic encapsulation layer43ranges from 0.5 μm to 2 μm. A thickness of the organic adhesive layer ranges from 10 μm to 25 μm. A thickness of the viscosity-reducing adhesive layer ranges from 15 μm to 50 μm.

In another embodiment, as shown inFIG.3, the display panel further includes a moisture-absorbing layer50. The moisture-absorbing layer50is disposed between the first inorganic encapsulation layer30and the organic adhesive layer44. The moisture-absorbing layer50covers part of the array substrate layer10, the lateral wall of the first inorganic encapsulation layer30, and part of an upper surface of the first inorganic encapsulation layer30. The organic adhesive layer44covers all of an upper surface of the moisture-absorbing layer50. Material of the moisture-absorbing layer50includes, but is not limited to, a moisture-absorbing substance including an acrylic organic matter, an epoxy organic matter, or a combination thereof. The moisture-absorbing layer50is disposed on a lateral edge of the first inorganic encapsulation layer. The moisture-absorbing layer50is configured to absorb external moisture entering the display panel, thereby extending an entering path of moisture and improving an encapsulation effect of the encapsulation layer. Furthermore, the thickness of the moisture-absorbing layer50covering the array substrate layer20is greater than a sum of the thickness of the first inorganic encapsulation layer30and the thickness of the display functional layer20. A width of the moisture-absorbing layer50can be designed according to a moisture-absorbing capability of material of the moisture-absorbing layer and a coating quality of the moisture-absorbing layer50.

The present disclosure further provides a method of manufacturing a display device. Please refer toFIG.4andFIG.5.FIG.4is a flowchart showing the method of manufacturing the display device provided by the embodiment of the present disclosure.FIG.5is a structural schematic view showing the method of manufacturing the display device provided by the embodiment of the present disclosure. The method includes following steps.

In a panel-manufacturing workshop, the method includes following steps:step S11, providing a base, and sequentially manufacturing a viscosity-reducing adhesive layer, a second inorganic encapsulation layer, and an organic adhesive layer on the base to obtain a composite barrier layer;step S12, manufacturing a first inorganic encapsulation layer on an array substrate and a display functional layer;Step S13, attaching the composite barrier layer to the first inorganic encapsulation layer to obtain the display panel of any of the above embodiments, wherein the organic adhesive layer is in contact with the first inorganic encapsulation layer; andstep S2, transporting the display panel from the panel-manufacturing workshop to a module-manufacturing workshop;wherein in the module-manufacturing workshop, the method comprises the following steps:step S31, performing a viscosity-reducing process on the viscosity-reducing adhesive layer to reduce viscosity of the viscosity-reducing adhesive layer; andstep S32, removing the viscosity-reducing adhesive layer and the base.

Specifically, in the step S11of providing the base, and sequentially manufacturing the viscosity-reducing adhesive layer, the second inorganic encapsulation layer, and the organic adhesive layer on the base to obtain the composite barrier layer, the method includes following steps:providing the base;forming the viscosity-reducing adhesive layer on the base by coating, ink-jet printing, or attaching, wherein a thickness of the viscosity-reducing adhesive layer ranges from 15 μm to 50 μm;manufacturing the second inorganic encapsulation layer on the viscosity-reducing adhesive layer by chemical vapor deposition (CVD) or atomic layer deposition (ALD), wherein a projection of the second inorganic encapsulation layer on the base is located in a projection of the viscosity-reducing adhesive layer on the base, a distance between a lateral edge of the second inorganic encapsulation layer and a lateral edge of the viscosity-reducing adhesive layer is greater than 1 mm, and a thickness of the second inorganic encapsulation layer ranges from 0.5 μm to 2 μm; andforming the organic adhesive layer on the second inorganic encapsulation layer by coating, ink-jet printing, or attaching, wherein a lateral edge of the organic adhesive layer is aligned with the lateral edge of the second inorganic encapsulation layer, a thickness of the organic adhesive layer ranges from 10 μm to 25 μm, and a release film is attached to a surface of the organic adhesive layer away from the second inorganic encapsulation layer.

In the step S12of manufacturing the first inorganic encapsulation layer on the array substrate and the display functional layer, the method comprises a following step:manufacturing the first inorganic encapsulation layer on the array substrate and the display functional layer by CVD or ALD, wherein the first inorganic encapsulation layer covers all of the display functional layer and part of the array substrate layer, a distance X1between a lateral wall of the first inorganic encapsulation layer and a lateral wall of the display functional layer is greater than 200 μm, and a thickness of the first inorganic encapsulation layer ranges from 0.3 μm to 1 μm, which can be referred toFIG.5(a).

A step may be conducted between the step S12and the step1. The step includes:manufacturing the moisture-absorbing layer on the array substrate and the first inorganic encapsulation layer by coating or ink-jet printing, which can be referred toFIG.5(b).

In the step S13of attaching the composite barrier layer to the first inorganic encapsulation layer, the method includes following steps:removing the release film on the surface of the second inorganic encapsulation layer; andattaching the composite barrier layer to the first inorganic encapsulation layer, which can be referred toFIG.5(c).

In the step S31of performing the viscosity-reducing process on the viscosity-reducing adhesive layer to reduce viscosity of the viscosity-reducing adhesive layer, the method includes following steps:when the viscosity-reducing adhesive layer is an ultraviolet viscosity-reducing adhesive layer, irradiating the viscosity-reducing adhesive layer is irradiated with ultraviolet light to reduce viscosity of the viscosity-reducing adhesive layer below 2 gf/25 mm; andwhen the viscosity-reducing adhesive layer is a heat viscosity-reducing adhesive layer, heating the viscosity-reducing adhesive layer to reduce viscosity of the viscosity-reducing adhesive layer below 2 gf/25 mm.

In the step S32of removing the viscosity-reducing adhesive layer and the base, the method includes a following step:removing the viscosity-reducing adhesive layer after the viscosity-reducing process is conducted, and simultaneously removing the base, which can be referred toFIG.5(d).

After the step S32, the method further includes steps such as assembling an edge frame and compressing a driving circuit board.

In summary, embodiments of the present disclosure provide a display panel and a method of manufacturing a display device. In the present disclosure, first, a second inorganic encapsulation layer and an organic encapsulation layer are manufactured on a base having a viscosity-reducing adhesive layer to form a composite barrier layer. Then, the composite barrier layer is attached to a first inorganic encapsulation layer disposed on a display functional layer. Therefore, an encapsulation layer of the display panel can be well protected when the display panel is transported from a panel-manufacturing workshop to a module-manufacturing workshop. Furthermore, defects of the second inorganic encapsulation layer and/or the organic encapsulation layer can be found in time, so that an unqualified composite barrier layer can be removed. Moreover, since manufacturing processes of the encapsulation layer of the display panels are changed from including three manufacturing steps of CVD, ink-jet printing, and another CVD to including two steps of CVD and attaching. As such, the manufacturing processes of the encapsulation layer are simplified. Thus, time required for manufacturing the encapsulation layer is reduced, an issue of large impurity particles damaging the display panel is prevented, and a yield rate of the display panel is improved.

A display panel and a method of manufacturing a display device have been described in detail by the above embodiments, which illustrate principles and implementations thereof. However, the description of the above embodiments is only for helping to understand the technical solution of the present disclosure and core ideas thereof, and it is understood by those skilled in the art that many changes and modifications to the described embodiment can be carried out without departing from the scope and the spirit of the disclosure that is intended to be limited only by the appended claims.