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 and deformation of light-emitting layers during deposition, which affects the arrangement and spacing of color light-emitting elements.
Innovation Solution
A display panel design with specific pixel arrangements and a deposition apparatus using multiple mask assemblies with staggered openings to ensure precise deposition of light-emitting layers, maintaining a high process margin and reducing misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple mask assemblies are used to deposit light-emitting layers for different pixel types, then the aperture ratio can be improved through optimized pixel arrangement, but misalignment and deformation of light-emitting layers occur during deposition
Solution Approach 1:
The patent divides the pixel array into two types: first pixels with a first arrangement pattern and second pixels with a second arrangement pattern. Different mask assemblies are used for each pixel type, with each mask having openings arranged according to its corresponding pixel type. This segmentation allows optimized aperture ratios for each pixel type while maintaining manufacturing precision through dedicated masking for each pattern.
2Reliability
If the minimum distance between adjacent light-emitting elements is increased to reduce defects, then the aperture ratio improves, but the pixel density and display resolution may be reduced
Solution Approach 1:
The patent applies different spacing configurations to different pixel types. First pixels have a first minimum distance between adjacent light-emitting elements, while second pixels have a second minimum distance. This local differentiation allows optimization of defect reduction in specific regions while maintaining higher pixel density in other regions, achieving both reliability and area efficiency.
3Device complexity
If a single mask assembly is used for all pixels, then the device complexity is reduced, but it cannot accommodate different arrangement patterns for different pixel types
Solution Approach 1:
The patent designs mask assemblies that can serve multiple functions: each mask assembly is specifically configured for a particular pixel type (first or second pixels), but the overall system uses these specialized masks in a universal deposition process. The masks are designed with opening patterns that match their corresponding pixel types, allowing one mask assembly to handle all pixels of its designated type across the entire display panel.
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
The solution enhances the aperture ratio and reduces defects by ensuring accurate placement and spacing of color light-emitting elements, improving the manufacturing efficiency and quality of display panels.
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.