Organic light-emitting diode (OLED) display panel and manufacturing method thereof

• US 10,818,876 B2
• Filed: 09/12/2018
• Issued: 10/27/2020
• Est. Priority Date: 04/25/2018
• Status: Active Grant

• Current Assignee: Shenzhen China Star Optoelectronics Technology Co., Ltd. (TCL Technology Group Corp.)
• Original Assignee: Shenzhen China Star Optoelectronics Technology Co., Ltd. (TCL Technology Group Corp.)
• Inventors: Huang, Hui
• Primary Examiner(s): Fernandes, Errol V
• Assistant Examiner(s): Joy, Jeremy J
• Application Number:
  US16/091,014
• Publication Number:
  US 20200168842A1
• Time in Patent Office: 776 Days
• CPC Class Codes: H10K 50/844 Encapsulations
• CPC Class Codes: H10K 50/8445 multilayered coatings having a repetitive structure, e.g. having multiple organic-inorganic bilayers
• CPC Class Codes: H10K 50/858 comprising refractive means, e.g. lenses
• CPC Class Codes: H10K 59/12 Active-matrix OLED [AMOLED] displays
• CPC Class Codes: H10K 59/1201 Manufacture or treatment
• CPC Class Codes: H10K 59/35 comprising red-green-blue [RGB] subpixels
• CPC Class Codes: H10K 59/38 comprising colour filters or colour changing media [CCM]
• CPC Class Codes: H10K 71/00 Manufacture or treatment specially adapted for the organic devices covered by this subclass
• CPC Class Codes: H10K 77/111 Flexible substrates

Abstract

The present disclosure relates to an organic light-emitting diode (OLED) display panel, including: a substrate, an OLED array layer configured on the substrate, a thin film packaging layer configured on the substrate and the OLED array layer, and a light extraction layer configured within the thin film packaging layer. The OLED array layer includes a plurality of OLED components arranged in matrix. The thin film packaging layer includes at least two inorganic barrier layers and at least one organic buffer layer. One side of the inorganic barrier layer facing away the substrate includes a plurality of pixel grooves corresponding to tops of each of the OLED components. The light extraction layer is configured within the pixel grooves, and the light extraction layer is covered by a flattening film configured to seal the light extraction layer within the pixel grooves, so as to flatten a surface of the inorganic barrier layer.

Claims

1. An organic light-emitting diode (OLED) display panel, comprising:

a substrate;

an OLED array layer configured on the substrate;

a thin film packaging layer configured on the substrate and the OLED array layer; and

a light extraction layer configured within the thin film packaging layer;

wherein the OLED array layer comprises a plurality of OLED components arranged in matrix, the thin film packaging layer comprises at least two inorganic barrier layers and at least one organic buffer layer, one side of one of the at least two inorganic barrier layers facing away the substrate comprises a plurality of pixel grooves corresponding to tops of OLED devices, the light extraction layer is configured within the pixel grooves, and the light extraction layer is covered by a flattening film configured to seal the light extraction layer within the pixel grooves, so as to flatten a surface of the one of the at least two inorganic barrier layers.

2. The OLED display panel according to claim 1, wherein a number of the organic buffer layers is one less than a number of the inorganic barrier layers in the thin film packaging layer, the inorganic barrier layers and the organic buffer layers are stacked in an alternative manner, and a most-bottom layer of the thin film packaging layer is configured to be an inorganic barrier layer.

3. The OLED display panel according to claim 2, wherein the thin film packaging layer comprises three inorganic barrier layers, the pixel grooves are configured on a second inorganic barrier layer arranged along a direction from a bottom to a top, in the thin film packaging layer, and the light extraction layer is configured within the second inorganic barrier layer arranged along the direction from the bottom to the top.

4. The OLED display panel according to claim 1, wherein the light extraction layer is made of titanium dioxide sol, magnesium oxide sol, or an organic solution;

the flattening film is made of a same material as the at least two inorganic barrier layers;

the at least two inorganic barrier layers are made of silicon nitride; and

the at least one organic buffer layer is made of silicon carbon nitride or silicon oxide carbon.

5. The OLED display panel according to claim 1, further comprising a thin film transistor (TFT) layer configured between the substrate and the OLED array layer, and a color filter layer configured within the thin film packaging layer, wherein the OLED array layer is configured on the TFT layer;

the substrate is a flexible substrate; and

the OLED components comprise;

a plurality of red OLED components, a plurality of green OLED components, and a plurality of blue OLED components;

or

the OLED components are configured to be white OLED components.

6. A manufacturing method of an OLED display panel, comprising:

providing a substrate;

forming an OLED array layer on the substrate, wherein the OLED array layer comprises a plurality of OLED components arranged in matrix;

forming a thin film packaging layer on the substrate and the OLED array layer, and forming a light extraction layer configured within the thin film packaging layer;

wherein the thin film packaging layer comprises at least two inorganic barrier layers and at least one organic buffer layer, a plurality of pixel grooves are formed on one side of one of the at least two inorganic barrier layers facing away the substrate corresponding to tops of each of the OLED components, a light extraction material is deposited within the pixel grooves to form the light extraction layer, and an inorganic material is filled within the pixel grooves to form a flattening film configured to cover the light extraction layer, so as to flatten a surface of the one of the at least two inorganic barrier layers.

7. The manufacturing method according to claim 6, wherein a number of the organic buffer layers is one less than a number of the inorganic barrier layers in the thin film packaging layer, the inorganic barrier layers and the organic buffer layers are stacked in an alternative manner, and a most-bottom layer of the thin film packaging layer is configured to be the inorganic barrier layer;

the at least two inorganic barrier layers are manufactured by conducting a chemical vapor deposition (CVD) process; and

the pixel grooves are formed by conducting a patterning process, wherein the patterned process comprises a photoresist-coating process, an exposure process, a development process, an etching process, and a photoresist-removing process conducted in sequence.

8. The manufacturing method according to claim 7, wherein the thin film packaging layer comprises three inorganic barrier layers, the pixel grooves are configured on a second inorganic barrier layer arranged along a direction from a bottom to a top, in the thin film packaging layer, and the light extraction layer is configured within the second inorganic barrier layer, arranged along the direction from the bottom to the top.

9. The manufacturing method according to claim 6, wherein the light extraction material is titanium dioxide sol, magnesium oxide sol, or an organic solution, and the light extraction material is deposited by conducting a coating process, an evaporation process, or a spraying process;

the flattening film is made of a same material as the at least two inorganic barrier layers;

the at least two inorganic barrier layer is layers are made of silicon nitride; and

the at least one organic buffer layer is made of silicon carbon nitride or silicon oxide carbon.

10. The manufacturing method according to claim 6, further comprising forming a TFT layer on the substrate before forming the OLED array layer and forming a color filter layer configured within the thin film packaging layer, wherein the OLED array layer is configured on the TFT layer;

the substrate is a flexible substrate; and

the OLED components comprise;

a plurality of red OLED components, a plurality of green OLED components, and a plurality of blue OLED components;

or

the OLED components are configured to be white OLED components.