TWI872862B - Display panel and manufacturing method thereof - Google Patents

Abstract

A display includes a first display area, a second display area, and a third display area. The first display area includes a plurality of first island areas, a plurality of first bridge areas and a plurality of first hollow areas. The first island areas are separated from each other. The first bridge areas connect two adjacent first island areas respectively, and each first hollow area is surrounded by four adjacent first island areas and four adjacent first bridge areas. The second display area includes a plurality of second island areas, a plurality of second bridge areas and a plurality of second hollow areas. The second island areas are separated from each other. The second bridge areas connect two adjacent second island areas respectively, and each second hollow area is surrounded by four adjacent second island areas and four adjacent second bridge areas. The size of each second hollow area is different from the size of each first hollow area. The second display area is disposed between the first display area and the third display area.

Description

Display panel and manufacturing method thereof

The present disclosure provides a display panel and a method for manufacturing the display panel, in particular, a flexible display panel and a method for manufacturing the flexible display panel.

At present, flexible display panels are developing from two-dimensional deformability to three-dimensional deformability. In order to increase the deformability of flexible display panels, a series of openings are generally set on the flexible substrate, divided into: an island area where pixels are located and a bridge area where connecting lines are located, so that the display panel has the performance of stretchable deformation. Pixels are set in the island area, and signal wiring is arranged on the bridge area. When external force is applied, deformation mainly occurs in the bridge area, and the pixels in the island area basically maintain their shape. For a flexible display panel, the display screen includes a non-stretchable display area and a stretchable display area. The pixel design of the stretchable display area is formed by removing a part of the pixels in situ on the basis of the pixel design of the non-stretchable display area. For example, the pixel arrangement of the non-stretchable display area is formed by removing the pixels at the corresponding opening position, that is, in the stretchable display area, the pixels at the corresponding opening position are removed. When the stretchable display area is not stretched and deformed, its pixel distribution is uniform and consistent with that of the non-stretchable display area, and the display brightness is uniform. However, when stretched and deformed, the uniformity of pixel distribution is broken, the pixel density of the stretchable display area decreases, causing the brightness and resolution of the stretchable display area to decrease, resulting in a difference between the luminous brightness and resolution of the display panel in the overall stretchable display area and the luminous brightness and resolution of the non-stretchable display area.

The present disclosure provides a display panel, which includes a first display area, a second display area and a third display area. The first display area includes a plurality of first island areas, a plurality of first bridge areas and a plurality of first basket empty areas. The first island areas are separated from each other, the first bridge areas are respectively connected to two adjacent first island areas, and each first basket empty area is surrounded by four adjacent first island areas and four adjacent first bridge areas. The second display area includes a plurality of second island areas, a plurality of second bridge areas and a plurality of second basket empty areas. The second island areas are separated from each other, the second bridge areas are respectively connected to two adjacent second island areas, and each second basket empty area is surrounded by four adjacent second island areas and four adjacent second bridge areas. The size of each second basket empty area is different from the size of each first basket empty area. The second display area is located between the first display area and the third display area.

According to one or more embodiments of the present disclosure, each first basket empty area has a first long axis, and the second display area includes a first sub-display area, a second sub-display area, and a third sub-display area. The first sub-display area is adjacent to the first display area. The first sub-display area includes the 2-1 basket empty area, and the 2-1 basket empty area has a second long axis, and the second long axis is 2/3 times the first long axis. The second sub-display area includes the 2-2 basket empty area, and the 2-2 basket empty area has a third long axis, and the third long axis is 1/3 times the first long axis. The third sub-display area is adjacent to the third display area. The third sub-display area includes the 2-3 basket empty area, and the 2-3 basket empty area has a fourth long axis, and the fourth long axis is 1/6 times the first long axis. The second sub-display area is located between the first sub-display area and the third sub-display area.

According to one or more embodiments of the present disclosure, each first island region includes a plurality of first sub-pixels, and a first sub-pixel spacing exists between two adjacent first sub-pixels. The width of the first sub-display region is the same as the first sub-pixel spacing, the width of the second sub-display region is twice the first sub-pixel spacing, and the width of the third sub-display region is twice the first sub-pixel spacing.

According to one or more embodiments of the present disclosure, each first island includes a plurality of first sub-pixels, and a first sub-pixel spacing exists between two adjacent first sub-pixels. Each second island includes a plurality of second sub-pixels, and a second sub-pixel spacing exists between two adjacent second sub-pixels. The third display area includes a plurality of third sub-pixels, and a third sub-pixel spacing exists between two adjacent third sub-pixels. The third sub-pixel spacing is smaller than the first sub-pixel spacing, and the second sub-pixel spacing is the same as the first sub-pixel spacing.

According to one or more embodiments of the present disclosure, the area of the third display region is greater than 1/6 times the area of the display panel and less than 8/9 times the area of the display panel.

According to one or more embodiments of the present disclosure, the first display area has a first forming strain rate, the second display area has a second forming strain rate, and the third display area has a third forming strain rate. The first forming strain rate is greater than the second forming strain rate, and the second forming strain rate is greater than the third forming strain rate.

Another aspect of the present disclosure provides a method for manufacturing a display panel, which includes the following operations. Pressing a laminated flexible substrate and simulating the stress distribution required for the forming operation. According to the stress distribution, the laminated flexible substrate is divided into a first display area, a second display area, and a third display area, and the second display area is located between the first display area and the third display area, wherein the first display area, the second display area, and the third display area each have a different forming strain rate. The laminated flexible substrate is subjected to a process sequence to form a display panel structure. Performing a forming operation to obtain a display panel.

According to one or more embodiments of the present disclosure, the process sequence includes: forming a plurality of first islands, a plurality of first bridges, and a plurality of first basket spaces in a first display area, wherein the first islands are separated from each other, the first bridges are respectively connected to two adjacent first islands, and each first basket space is surrounded by four adjacent first islands and four adjacent first bridges; and forming a plurality of second islands, a plurality of second bridges, and a plurality of second basket spaces in a second display area, wherein the second islands are separated from each other, the second bridges are respectively connected to two adjacent second islands, and each second basket space is surrounded by four adjacent second islands and four adjacent second bridges, wherein the size of each second basket space is different from the size of each first basket space.

According to one or more embodiments of the present disclosure, forming a plurality of second hollow areas in the second display area includes: dividing the second display area into a first sub-display area, a second sub-display area, and a third sub-display area, wherein the first sub-display area is adjacent to the first display area, the third sub-display area is adjacent to the third display area, and the second sub-display area is located between the first sub-display area and the third sub-display area; forming a first mask on a portion of the first sub-display area; forming a second mask on a portion of the second sub-display area; forming a third mask on a portion of the third sub-display area, wherein the thickness of the third mask is greater than the thickness of the second mask, and the thickness of the second mask is greater than the thickness of the first mask; and performing an etching process to form these second hollow areas.

According to one or more embodiments of the present disclosure, the width of the second mask is substantially the same as the width of the first mask, and the width of the third mask is 2/3 times the width of the second mask.

10: Methods

102: Operation

104: Operation

106: Operation

108: Operation

20: Laminated soft substrate

210: Carrier film

230: Display substrate

30: Display panel

400: First display area

410: First Island Area

412: First sub-pixel

412D: first sub-pixel spacing

430: First Bridge Area

450: The first empty area

500: Second display area

500A: First sub-display area

500B: Second sub-display area

500C: The third sub-display area

500W: Width

510: Second Island Area

512: Second sub-pixel

512D: Second sub-pixel spacing

530: Second Bridge Area

550: Second empty area

550A: No. 2-1 empty area

550B: No. 2-2 empty area

550C: 2nd-3rd empty area

600: The third display area

612: The third sub-pixel

612D: Third sub-pixel spacing

6-6’: Line

7-7’: Line

h1: long axis

h2: long axis

h3: Long axis

h4: Long axis

M0: Standard mask

M1: First mask

M2: Second mask

M3: The third mask

T0: thickness

T1:Thickness

T2: Thickness

T3:Thickness

W1: Width

W2: Width

W3: Width

WA: Width

WB: Width

WC: Width

Various aspects of the present disclosure will be best understood from the following detailed description when read in conjunction with the accompanying drawings. It is noted that, in accordance with standard industry practice, the various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

Figure 1 is a flow chart of a method for manufacturing a display panel according to an embodiment of the present disclosure.

Figure 2 is a cross-sectional view of a display panel at a certain stage of the manufacturing process according to an embodiment of the present disclosure.

Figure 3 is a top view of a display panel according to an implementation method of the present disclosure.

Figure 4 is a top view of a portion of a display panel according to an embodiment of the present disclosure.

Figure 5 is a top view of the second display area of the display panel according to an embodiment of the present disclosure.

FIG. 6 is a cross-sectional view of the second display area of a display panel according to an embodiment of the present disclosure at a certain stage of the manufacturing process along the line 6-6' in FIG. 5.

FIG. 7 is a cross-sectional view of the first display area of a display panel according to an embodiment of the present disclosure at a certain stage of the manufacturing process along the line 7-7' in FIG. 4.

The following will use diagrams and detailed descriptions to clearly illustrate the spirit of this disclosure. After understanding the preferred embodiments of this disclosure, any person with ordinary knowledge in the relevant technical field can make changes and modifications based on the techniques taught by this disclosure without departing from the spirit and scope of this disclosure.

In the accompanying drawings, the thickness of layers, films, panels, regions, etc., is exaggerated for clarity. Throughout the specification, the same figure reference numerals represent the same elements. It should be understood that when an element such as a layer, film, region, or substrate is referred to as being "on" or "connected to" another element, it can be directly on or connected to another element, or an intermediate element may also exist. In contrast, when an element is referred to as being "directly on" or "directly connected to" another element, there are no intermediate elements. As used herein, "connected" may refer to physical and/or electrical connections. Furthermore, "electrically connected" or "coupled" may be the presence of other elements between two elements.

Additionally, relative terms such as "lower" or "bottom" and "upper" or "top" may be used herein to describe the relationship of one element to another element, as shown in the figures. It should be understood that relative terms are intended to include different orientations of the device in addition to the orientation shown in the figures. For example, if the device in one of the figures is flipped, the elements described as being on the "lower" side of the other elements will be oriented on the "upper" side of the other elements. Thus, the exemplary term "lower" can include both "lower" and "upper" orientations, depending on the particular orientation of the figure. Similarly, if the device in one of the figures is flipped, the elements described as being "below" or "beneath" the other elements will be oriented as being "above" the other elements. Thus, the exemplary term "below" or "beneath" can include both "upper" and "lower" orientations.

According to one aspect of the present disclosure, a method 10 for manufacturing a display panel (such as the display panel 30 shown in FIGS. 3 and 4) is provided. FIG. 1 is a flow chart of the method 10 for manufacturing a display panel according to an embodiment of the present disclosure. The method 10 includes operations 102, 104, 106, and 108.

Various operations of embodiments are provided herein. The order in which some or all operations are described should not be interpreted as implying that these operations are necessarily order-dependent. With the benefit of this description, alternative orderings will be understood. Furthermore, it should be understood that not all operations must be present in every embodiment provided herein. Moreover, it should be understood that not all operations are required in some embodiments.

FIG. 2 is a cross-sectional view of a display panel at a certain stage of the manufacturing process according to an embodiment of the present disclosure. In operation 102, the laminated flexible substrate 20 is pressed and the stress distribution required for the forming operation is simulated, as shown in FIG. 2. In some embodiments, the laminated flexible substrate 20 may include a carrier film 210 and a display substrate 230. For example, the carrier film 210 is a stretchable soft plastic substrate, which can be made of a polymer material, such as polyimide (PI), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycarbonate (PC), polyether sulfone (PES) or polyarylate, or a combination thereof. For example, the display substrate 230 is a stretchable soft display substrate. In other embodiments, the laminated soft substrate 20 may include the carrier film 210, the display substrate 230 and a cover glass (not shown) laminated in sequence. For example, the glass cover can be made of glass or acrylic. More specifically, during the pressing process, finite element simulation software such as ANSYS, ABAQUS, and MSC.Nastran can be used to simulate the stress distribution required for subsequent forming operations.

FIG. 3 is a top view of a display panel 30 according to an embodiment of the present disclosure. In operation 104, the laminated flexible substrate is divided into a first display area 400, a second display area 500, and a third display area 600 according to stress distribution, wherein the first display area 400, the second display area 500, and the third display area 600 each have a different forming strain rate, as shown in FIG. 3. Generally speaking, the area with the largest forming strain rate is mostly concentrated at the edge of the substrate, and the area with the smallest forming strain rate is mostly concentrated at the center of the substrate. For example, the area with a forming strain rate greater than 4% can be divided into a first display area 400, the area with a forming strain rate less than 1% can be divided into a third display area 600, and the area with a forming strain rate between 1% and 4% can be divided into a second display area 500 (also called a transition area).

In other embodiments, the laminated flexible substrate may be divided into a first display region, a second display region, a third display region, a fourth display region, and a fifth display region according to stress distribution. For example, a region with a forming strain rate greater than 7% may be divided into a first display region, a region with a forming strain rate between 3% and 4% may be divided into a third display region, a region with a forming strain rate less than 1% may be divided into a fifth display region, a region with a forming strain rate between 4% and 7% may be divided into a second display region (which may be referred to as a first transition region), and a region with a forming strain rate between 1% and 2% may be divided into a fourth display region (which may be referred to as a second transition region). However, the present disclosure is not limited to this, and can be designed according to product requirements, different forming stress distribution, and multiple display areas can be divided so that these display areas have different pixel densities (Pixels Per Inch, PPI).

FIG. 4 is a top view of a portion of a display panel according to an embodiment of the present disclosure. In operation 106, a process sequence is performed on the laminated flexible substrate 20 to form a display panel structure, as shown in FIG. 4. In some embodiments, the process sequence includes forming a plurality of first island regions 410, a plurality of first bridge regions 430, and a plurality of first basket empty regions 450 in the first display region 400, and forming a plurality of second island regions 510, a plurality of second bridge regions 530, and a plurality of second basket empty regions 550 in the second display region 500. Specifically, a plurality of first islands 410 are separated from each other, a plurality of first bridges 430 are respectively connected to two adjacent first islands 410, and each first basket space 450 is surrounded by four adjacent first islands 410 and four adjacent first bridges 430. A plurality of second islands 510 are separated from each other, a plurality of second bridges 530 are respectively connected to two adjacent second islands 510, and each second basket space 550 is surrounded by four adjacent second islands 510 and four adjacent second bridges 530. It is worth noting that the size of each second basket space 550 is different from the size of each first basket space 450. For example, the size of each second basket space 550 is larger than the size of each first basket space 450.

FIG. 5 is a top view of the second display area 500 of the display panel 30 according to an embodiment of the present disclosure. FIG. 6 is a cross-sectional view of the second display area 500 of the display panel 30 according to an embodiment of the present disclosure along the line 6-6' in FIG. 5 at a certain stage of manufacturing. In more detail, as shown in FIG. 5, in some embodiments, forming a plurality of second basket empty areas 550 in the second display area 500 includes first dividing the second display area 500 into a first sub-display area 500A, a second sub-display area 500B, and a third sub-display area 500C. The first sub-display area 500A is adjacent to the first display area 400, the third sub-display area 500C is adjacent to the third display area 600, and the second sub-display area 500B is located between the first sub-display area 500A and the third sub-display area 500C. As shown in FIG. 5 and FIG. 6, a first mask M1 is then formed on a portion of the first sub-display area 500A, a second mask M2 is formed on a portion of the second sub-display area 500B, and a third mask M3 is formed on a portion of the third sub-display area 500C. It is worth noting that the thickness T3 of the third mask M3 is greater than the thickness T2 of the second mask M2, and the thickness T2 of the second mask M2 is greater than the thickness T1 of the first mask M1. For example, the thickness T1 of the first mask M1 may be between 1Å and 500Å, the thickness T2 of the second mask M2 may be between 500Å and 1000Å, and the thickness T3 of the third mask M3 may be between 1000Å and 1500Å.

In some embodiments, the width W3 of the third mask M3 is greater than the width W2 of the second mask M2, and the width W2 of the second mask M2 is substantially the same as the width W1 of the first mask M1. For example, the width W3 of the third mask M3 may be 2/3 times the width W2 of the second mask M2.

Please continue to refer to Figures 5 and 6. At the locations where multiple second bridge areas 530 are expected to be formed in the first sub-display area 500A, the second sub-display area 500B, and the third sub-display area 500C, a standard mask M0 will be formed, and the thickness T0 of the standard mask M0 will be greater than the thickness T3 of the third mask M3.

Then, an etching process is performed to simultaneously form these second basket spaces 550. It is understandable that the sizes of the second basket spaces 550 are not exactly the same. For example, the size of the second basket space 550 of the first sub-display area 500A is larger than the size of the second basket space 550 of the second sub-display area 500B, and the size of the second basket space 550 of the second sub-display area 500B is larger than the size of the second basket space 550 of the third sub-display area 500C.

FIG. 7 is a cross-sectional view of the first display area 400 of the display panel 30 according to an embodiment of the present disclosure at a certain stage of the manufacturing process along the line 7-7' in FIG. 4. In some embodiments, it is not necessary to form a mask at a plurality of locations in the first display area 400 where the first basket empty areas 450 are expected to be formed, and a standard mask M0 is formed at a plurality of locations in the first display area 400 where the first bridge areas 430 are expected to be formed, as shown in FIG. 7.

In addition, the process sequence also includes light-emitting element transfer and packaging process. For example, the light-emitting element is a micro-LED, and its size is, for example, in the micron level, such as less than 100 microns and greater than 0 microns, but the present disclosure is not limited to this. These micro-LEDs can be first formed on a growth substrate (not shown), and then transferred to the laminated flexible substrate 20 together using the mass transfer technology.

In operation 108, a forming operation is performed to obtain a display panel, such as the display panel 30 of Figures 3 and 4. The specific features and details of the display panel 30 will be described in more detail below.

According to another aspect of the present disclosure, a display panel 30 is provided. Referring to FIG. 3 and FIG. 4 simultaneously, the display panel 30 includes a first display area 400, a second display area 500, and a third display area 600, and the second display area 500 is located between the first display area 400 and the third display area 600. As described above, the division of these display areas is based on the stress distribution required by the subsequent forming operation during the pressing operation stage. In some embodiments, the first display area 400 has a first forming strain rate, the second display area 500 has a second forming strain rate, and the third display area 600 has a third forming strain rate, the first forming strain rate is greater than the second forming strain rate, and the second forming strain rate is greater than the third forming strain rate. It is understandable that, since the first display area 400 has a larger forming strain rate, the pixel density in the first display area 400 will be lower. Similarly, since the third display area 600 has a smaller forming strain rate, the pixel density in the third display area 600 will be higher. The second display area 500 is a transition area between the first display area 400 and the third display area 600, and the pixel density of the second display area 500 is defined as the same as the pixel density of the first display area.

In some embodiments, the size of each first island region 410 in the first display area 400 is the same as the size of each second island region 510 in the second display area 500. In some embodiments, the size of each first bridge region 430 in the first display area 400 is the same as the size of each second bridge region 530 in the second display area 500. It can be understood that the difference between the first display area 400 and the second display area 500 is that the size of the second basket empty area 550 is different from the size of the first basket empty area 450.

In some embodiments, the area of the third display region 600 is greater than 1/6 times the area of the display panel 30 and less than 8/9 times the area of the display panel 30.

In some embodiments, since the third display area 600 is subjected to a relatively small forming stress, the third display area 600 does not have any island area, bridge area, or hollow area design. It should be noted that, except for the third display area 600 which does not have an island area, a bridge area, or a hollow area, all features (such as size and shape) of the island area of the remaining display areas (such as the first display area 400 and the second display area 500) must be the same. In addition, except for the third display area 600, the shape and size of the bridge area of each display area may be different, but the shape and size of the bridge area of the same display area must be the same. For example, the bridge area 430 of the first display area 400 may all be arc-shaped, while the second bridge area 530 of the second display area 500 may all be serpentine. Therefore, it can be understood that all the features of the transition area (such as the second display area 500) (such as the island area size, the island area shape, and the sub-pixel spacing on the island area) are the same as those of the adjacent display area with lower pixel density (such as the first display area 400). The actual difference is that the size of the empty area of the transition area is different from that of the adjacent display area with lower pixel density (such as the first display area 400).

Please continue to refer to FIG. 3 and FIG. 4. Specifically, the first display area 400 includes a plurality of first island areas 410, a plurality of first bridge areas 430, and a plurality of first basket empty areas 450. These first island areas 410 are separated from each other, and these first bridge areas 430 respectively connect two adjacent first island areas 410, and each first basket empty area 450 is surrounded by four adjacent first island areas 410 and four adjacent first bridge areas 430. Similarly, the second display area 500 includes a plurality of second island areas 510, a plurality of second bridge areas 530, and a plurality of second basket empty areas 550. These second islands 510 are separated from each other, these second bridges 530 are respectively connected to two adjacent second islands 510, and each second basket space 550 is surrounded by four adjacent second islands 510 and four adjacent second bridges 530. It is worth noting that the size of each second basket space 550 is different from the size of each first basket space 450. In some embodiments, the size of each second basket space 550 is smaller than the size of each first basket space 450.

Please refer to FIG. 4 and FIG. 5 , the second display area 500 includes a first sub-display area 500A, a second sub-display area 500B and a third sub-display area 500C, the first sub-display area 500A is adjacent to the first display area 400, the third sub-display area 500C is adjacent to the third display area 600, and the second sub-display area 500B is located between the first sub-display area 500A and the third sub-display area 500C. In more detail, the first sub-display area 500A includes a 2-1 basket empty area 550A, and the 2-1 basket empty area 550A has a long axis h2. The second sub-display area 500B includes a 2-2 basket empty area 550B, and the 2-2 basket empty area 550B has a long axis h3. The third sub-display area 500C includes a 2-3rd basket empty area 550C, and the 2-3rd basket empty area 550C has a long axis h4. Returning to FIG. 4, each first basket empty area 450 of the first display area 400 has a long axis h1. In some embodiments, the long axis h1 of the first basket empty area 450 is greater than the long axis h2 of the 2-1st basket empty area 550A, the long axis h2 of the 2-1st basket empty area 550A is greater than the long axis h3 of the 2-2nd basket empty area 550B, and the long axis h3 of the 2-2nd basket empty area 550B is greater than the long axis h4 of the 2-3rd basket empty area 550C. For example, the long axis h2 of the 2-1st basket empty area 550A is 2/3 times the long axis h1 of the first basket empty area 450. The long axis h3 of the 2-2nd basket empty area 550B is 1/3 times the long axis h1 of the first basket empty area 450. The long axis h4 of the 2-3rd basket empty area 550C is 1/6 times the long axis h1 of the first basket empty area 450.

Please return to Figure 4. In some embodiments, each first island 410 includes a plurality of first sub-pixels 412, and a first sub-pixel spacing 412D is provided between two adjacent first sub-pixels 412. Each second island 510 includes a plurality of second sub-pixels 512, and a second sub-pixel spacing 512D is provided between two adjacent second sub-pixels 512. The third display area 600 includes a plurality of third sub-pixels 612, and a third sub-pixel spacing 612D is provided between two adjacent third sub-pixels 612. It should be noted that the third sub-pixel spacing 612D is smaller than the first sub-pixel spacing 412D, and the second sub-pixel spacing 512D is the same as the first sub-pixel spacing 412D.

Please continue to refer to Figure 4. In some embodiments, the second display area 500 has a width of 500W, and the width 500W is 3 to 6 times the first sub-pixel spacing 412D.

In some embodiments, each of the first sub-pixels 412, each of the second sub-pixels 512, and each of the third sub-pixels 612 may be independently an organic light emitting diode (OLED) or a light emitting diode (LED), such as a micro LED (μLED) or a sub-millimeter light emitting diode (mini LED). It is understood that at least three sub-pixels may constitute one pixel, such as a red sub-pixel, a green sub-pixel, and a blue sub-pixel, so that each pixel can emit a variety of different colors of light, such as red light, green light, blue light, or a combination thereof. In the embodiment of Figure 4, one pixel includes six sub-pixels, for example, two red sub-pixels, two green sub-pixels and two blue sub-pixels, of which one red sub-pixel, one green sub-pixel and one blue sub-pixel are used as main light-emitting sub-pixels, and the other three red sub-pixels, green sub-pixels and blue sub-pixels are used as spare sub-pixels. That is, in the lighting test, the main light-emitting sub-pixel can be tested to determine whether its light emission fails, and if it fails, the spare sub-pixel is turned on to replace it.

Referring to FIG. 5, in some embodiments, the width WA of the first sub-display area 500A is the same as the first sub-pixel spacing 412D, the width WB of the second sub-display area 500B is twice the first sub-pixel spacing 412D, and the width WC of the third sub-display area 500C is twice the first sub-pixel spacing 412D.

In summary, the display panel disclosed in the present invention simulates the stress distribution of the subsequent molding operation during the manufacturing process, and divides the substrate into different pixel densities according to the stress distribution, and also adds a transition zone between the high pixel density zone and the low pixel density zone, thereby further improving the elastic deformation ability and resolution of the display panel. In addition, when the display panel is stretched and deformed, the pixel distribution of the transition zone and the low pixel density zone is uniform and consistent with the pixel distribution of the high pixel density zone, so that the overall display brightness and resolution of the display panel are more uniform.

Although the present disclosure has been disclosed in the form of implementation as above, it is not intended to limit the present disclosure. Anyone skilled in the art can make various changes and modifications without departing from the spirit and scope of the present disclosure. Therefore, the protection scope of the present disclosure shall be subject to the scope of the patent application attached hereto.

30: Display panel

400: First display area

410: First Island Area

412: First sub-pixel

412D: first sub-pixel spacing

430: First Bridge Area

450: The first empty area

500: Second display area

500W: Width

510: Second Island Area

512: Second sub-pixel

512D: Second sub-pixel spacing

530: Second Bridge Area

550: Second empty area

600: Third display area

612: The third sub-pixel

612D: Third sub-pixel spacing

Claims (7)

A display panel comprises: a first display area, comprising a plurality of first island areas, a plurality of first bridge areas and a plurality of first basket empty areas, wherein the first island areas are separated from each other, the first bridge areas are respectively connected to two adjacent first island areas, and each first basket empty area is surrounded by four adjacent first island areas and four adjacent first bridge areas; a second display area, comprising a plurality of second island areas, a plurality of second bridge areas and a plurality of second basket empty areas, wherein the second island areas are separated from each other, the second bridge areas are respectively connected to two adjacent second island areas, and each second basket empty area is surrounded by four adjacent second island areas and four adjacent second bridge areas, wherein The size of each second basket empty area is different from the size of each first basket empty area; and a third display area, wherein the second display area is located between the first display area and the third display area, wherein each first island area includes a plurality of first sub-pixels, and a first sub-pixel spacing is provided between two adjacent first sub-pixels, each second island area includes a plurality of second sub-pixels, and a second sub-pixel spacing is provided between two adjacent second sub-pixels, and the third display area includes a plurality of third sub-pixels, and a third sub-pixel spacing is provided between two adjacent third sub-pixels, the third sub-pixel spacing is smaller than the first sub-pixel spacing, and the second sub-pixel spacing is the same as the first sub-pixel spacing. The display panel as described in claim 1, wherein each of the first basket empty areas has a first long axis, and the second display area includes: a first sub-display area, adjacent to the first display area, the first sub-display area includes a 2-1 basket empty area, the 2-1 basket empty area has a second long axis, and the second long axis is 2/3 times the first long axis; a second sub-display area, including a 2-2 basket empty area, the 2-1 basket empty area has a second long axis, and the second long axis is 2/3 times the first long axis. The 2-2 basket empty area has a third long axis, and the third long axis is 1/3 times the first long axis; and a third sub-display area, adjacent to the third display area, the third sub-display area includes a 2-3 basket empty area, the 2-3 basket empty area has a fourth long axis, and the fourth long axis is 1/6 times the first long axis, wherein the second sub-display area is located between the first sub-display area and the third sub-display area. A display panel as described in claim 2, wherein the width of the first sub-display area is the same as the first sub-pixel spacing, the width of the second sub-display area is twice the first sub-pixel spacing, and the width of the third sub-display area is twice the first sub-pixel spacing. A display panel as described in claim 1, wherein the area of the third display region is greater than 1/6 times the area of the display panel and less than 8/9 times the area of the display panel. A display panel as described in claim 1, wherein the first display area has a first forming strain rate, the second display area has a second forming strain rate, the third display area has a third forming strain rate, the first forming strain rate is greater than the second forming strain rate, and the second forming strain rate is greater than the third forming strain rate. A method for manufacturing a display panel includes: laminating a laminated flexible substrate and simulating a stress distribution required for a forming operation; dividing the laminated flexible substrate into a first display area, a second display area and a third display area according to the stress distribution, and the second display area is located between the first display area and the third display area, wherein the first display area, the second display area and the third display area each have a different forming strain rate; performing a process sequence on the laminated flexible substrate to form a display panel structure, wherein The process sequence includes: forming a plurality of first island regions, a plurality of first bridge regions and a plurality of first basket empty regions in the first display region, wherein the first island regions are separated from each other, the first bridge regions are respectively connected to two adjacent first island regions, and each first basket empty region is surrounded by four adjacent first island regions and four adjacent first bridge regions; and forming a plurality of second island regions, a plurality of second bridge regions and a plurality of second basket empty regions in the second display region, wherein the second island regions are separated from each other, the second bridge regions are respectively connected to each other. Connecting two adjacent second island areas, and each second basket area is surrounded by four adjacent second island areas and four adjacent second bridge areas, wherein the size of each second basket area is different from the size of each first basket area, wherein forming the second basket areas in the second display area includes: dividing the second display area into a first sub-display area, a second sub-display area and a third sub-display area, wherein the first sub-display area is adjacent to the first display area, the third sub-display area is adjacent to the third display area, and the The second sub-display area is located between the first sub-display area and the third sub-display area; a first mask is formed on a portion of the first sub-display area; a second mask is formed on a portion of the second sub-display area; a third mask is formed on a portion of the third sub-display area, wherein the thickness of the third mask is greater than the thickness of the second mask, and the thickness of the second mask is greater than the thickness of the first mask; and an etching process is performed to form the second empty areas; and the forming operation is performed to obtain the display panel. A method for manufacturing a display panel as described in claim 6, wherein the width of the second mask is substantially the same as the width of the first mask, and the width of the third mask is 2/3 times the width of the second mask.

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