Display Panel Pixel Layout for Precise Light-Emitting Layer Deposition
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Solution Overview
Problem
Existing display panels face challenges in achieving high aperture ratio and low defect ratio due to misalignment of light-emitting layers during the manufacturing process, particularly in the field of display panels, and the deposition of light-emitting layers, which can lead to inefficiencies and defects in the deposition process.
Innovation Solution
The display panel design includes two types of pixels with distinct arrangements of color light-emitting elements, and a deposition apparatus with three mask assemblies that are spaced and aligned to allow for precise deposition of light-emitting layers, enhancing the process margin and reducing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple mask assemblies are used to deposit light-emitting layers, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent divides the mask system into multiple separate mask assemblies (first, second, and third mask assemblies), each responsible for depositing specific color light-emitting layers. This segmentation allows each mask to be optimized for its specific function, improving alignment precision while managing complexity through modular design
Solution Approach 2:
The patent introduces a substrate as an intermediary element that features protrusions and recesses which interact with corresponding structures on the mask assemblies. This intermediary mechanism enables precise positioning and alignment of multiple light-emitting layers without requiring complex direct alignment between masks themselves
2Reliability
If the minimum distance between adjacent light-emitting elements is increased, then reliability is improved, but aperture ratio deteriorates
Solution Approach 1:
The patent utilizes the vertical dimension by creating protrusions and recesses that extend in the thickness direction of the substrate. This allows alignment features to occupy vertical space rather than horizontal space, enabling smaller horizontal distances between light-emitting elements while maintaining reliable alignment and reducing defects
Solution Approach 2:
The alignment structures are nested within the substrate thickness, with protrusions extending from one surface and corresponding recesses on the opposite surface. This nesting approach allows the alignment mechanism to be embedded within the substrate volume, preserving horizontal aperture area while ensuring proper positioning of light-emitting layers
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design improves the aperture ratio and reduces defects by ensuring accurate deposition of light-emitting layers, resulting in a more efficient and reliable manufacturing process.
Implementation Method 1
a light-emitting material may be deposited onto the work substrate and patterned, thereby forming light-emitting layers
Data Source
AI summary
A display panel includes first display regions, and a second display region between the two first display regions. Each of the first display regions includes first pixels. The second display region includes second pixels disposed in a second direction intersecting a first direction. Each of the second pixels include a first color light-emitting element, a second color light-emitting element, and a third color light-emitting element which are disposed in the first direction. An arrangement of the first color light-emitting element, the second color light-emitting element, and the third color light-emitting element of each of the first pixels may be different from an arrangement of the first color light-emitting element, the second color light-emitting element, and the third color light-emitting element of each of the second pixels.