Display Pixel Layout with Protruding Banks for Inkjet Alignment
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Solution Overview
Problem
Inkjet processes in organic light emitting display devices often result in ink misalignment and non-uniform layer heights due to alignment errors, leading to gap defects.
Innovation Solution
The display device is designed with alternating pixel arrangements, including protruding portions to prevent ink misadhesion during the inkjet process, ensuring precise placement and uniformity of color filters and light emitting layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If inkjet process is used to form organic light emitting diode and color conversion layer, then manufacturing flexibility and cost are improved, but ink alignment precision deteriorates causing misalignment and spill defects
Solution Approach 1:
The patent applies preliminary action by pre-forming bank structures with specific geometric configurations (protruding portions and recesses) before the inkjet deposition process. These pre-designed structural features create physical guides that constrain ink flow paths, ensuring precise ink placement within pixel regions even when inkjet alignment has minor deviations. The bank structures are prepared in advance to compensate for potential inkjet positioning errors.
Solution Approach 2:
The patent introduces bank structures as intermediary elements between the inkjet deposition system and the final pixel formation. These bank structures act as mediators that capture and contain the ink material, preventing spillage onto adjacent pixels. The protruding portions of the bank structures serve as intermediate containment barriers that guide ink into the correct pixel regions while blocking misaligned ink from affecting neighboring pixels.
2Reliability
If alternating pixel arrangements with protruding portions are implemented, then ink misadhesion prevention is improved, but device structure complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the pixel array into alternating first and second pixel areas with different arrangement patterns. The first pixel area contains pixels arranged in a specific configuration while the second pixel area uses a complementary configuration. This segmentation allows each region to benefit from optimized ink flow management tailored to its specific geometric characteristics, improving overall ink placement reliability while distributing the structural complexity across different regions.
Solution Approach 2:
The patent employs asymmetry by creating non-uniform pixel arrangements where protruding portions and recesses are positioned differently in alternating pixel areas. Rather than using a simple repeating pattern, the asymmetric design ensures that ink flow paths and containment structures vary between adjacent pixel regions, preventing systematic alignment errors from affecting all pixels uniformly and improving robustness against manufacturing variations.
Data Source
AI summary
A display device includes a display panel including a first pixel area and a second pixel area. The first pixel area includes a first pixel, a second pixel, and a third pixel, and the second pixel area includes a fourth pixel, a fifth pixel, and a sixth pixel. The first pixel and the second pixel are arranged to be adjacent to each other in a first direction, and the third pixel is arranged to be adjacent to the first pixel and the second pixel in a second direction that intersects the first direction. The third pixel and the fourth pixel emitting a same color are arranged to be adjacent to each other in the second direction, the fifth pixel is spaced apart from the first pixel in the second direction, and the sixth pixel is spaced apart from the second pixel in the second direction.