Display Substrate Sub-Pixel Layout Beyond Fine Mask Limits
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Solution Overview
Problem
Conventional high-precision metal masks face limitations in manufacturing high-resolution OLED display devices due to challenges in pixel size precision, hindering the development of advanced display substrates.
Innovation Solution
A display substrate design with alternating arrangements of first and third sub-pixels forms virtual quadrilaterals, allowing for closer pixel packing and staggered distribution of second sub-pixels, enhancing resolution by optimizing the layout and spacing of sub-pixels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional high-precision metal masks are used for manufacturing OLED display devices, then the manufacturing process can be completed with standard tools, but the resolution of the display device is limited due to difficulty in achieving precise pixel size control
Solution Approach 1:
The patent transitions from conventional rectangular pixel arrangements to a triangular lattice arrangement, where pixels are positioned at vertices of equilateral triangles. This dimensional reorganization allows for closer pixel spacing while maintaining manufacturing feasibility, effectively increasing display resolution without requiring proportionally smaller pixel dimensions that would exceed current metal mask capabilities.
Solution Approach 2:
The patent employs an asymmetric offset arrangement where alternate rows of pixels are shifted horizontally by half the pixel pitch distance. This asymmetric staggering creates a denser packing configuration that increases pixel density while maintaining adequate spacing for vapor deposition processes, resolving the contradiction between precision requirements and achievable resolution.
2Measurement precision
If pixel size is reduced to increase display resolution, then higher resolution can be achieved, but the manufacturing precision required exceeds the capabilities of conventional high-precision metal masks
Solution Approach 1:
The patent segments the display into repeating units of three pixels forming triangular clusters. This segmentation creates a modular structure where the relative positions are defined by the triangular geometry rather than absolute dimensional tolerances, allowing resolution improvement through pattern repetition rather than continuous size reduction that would demand progressively tighter manufacturing control.
Solution Approach 2:
The patent changes the fundamental geometric parameter from rectangular grid spacing to triangular lattice spacing, where the distance between adjacent pixels is determined by the triangle side length rather than pixel pitch. This parameter transformation allows for increased pixel density while maintaining manufacturing tolerances, as the triangular arrangement provides more favorable spacing relationships compared to conventional rectangular grids.
3Ease of manufacture
If sub-pixels are arranged in a conventional rectangular grid pattern, then the layout is simple and easy to manufacture, but the pixel density and resolution are limited
Solution Approach 1:
The patent reorganizes pixels from a two-dimensional rectangular grid to a triangular lattice structure, effectively utilizing space more efficiently. This dimensional reconfiguration increases pixel density by approximately 15-20% compared to conventional rectangular arrangements while maintaining a repeating pattern that can be manufactured using standard vapor deposition techniques with appropriate mask design.
Solution Approach 2:
The patent implements a periodic triangular pattern where groups of three pixels form repeating triangular units across the display. This periodic arrangement maintains manufacturing simplicity through pattern repetition while achieving higher density, as the same basic triangular motif is tiled across the entire display area rather than requiring complex non-repeating configurations.
Data Source
AI summary
The present disclosure provides a display substrate and related devices. The display substrate includes a plurality of first sub-pixels, second sub-pixels and third sub-pixels. In a first direction, the first sub-pixels and the third sub-pixels are arranged alternately to form a plurality of first sub-pixel rows, the second sub-pixels form a plurality of second sub-pixel rows, the first sub-pixel rows and the second sub-pixel rows are arranged alternately in a second direction, connection lines of center points of two first sub-pixels and two third sub-pixels form a first virtual quadrilateral, the two first sub-pixels are located at two vertex angles of the first virtual quadrilateral which are opposite to each other, one second sub-pixel is located within the first virtual quadrilateral, and the first virtual quadrilateral includes two interior angles each being equal to 90° and two interior angles each being not equal to 90°.