Hexagonal Pixel Layout for High-Resolution OLED Color Separation
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Solution Overview
Problem
The challenge of manufacturing high-resolution organic light emitting display devices is exacerbated by the difficulty in forming small opening patterns in masks, leading to reduced manufacturing yield and color mixing due to overlapping organic light emitting materials between adjacent pixels.
Innovation Solution
The display device is designed with a hexagonal unit area layout, featuring interlocked pixel columns and sub-pixel areas with specific border symmetries and distances, allowing for the deposition of distinct light emitting materials in separate openings, enhancing manufacturing yield and preventing color mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the size of one pixel is designed to be relatively small to display high-resolution image in limited display area, then the resolution is improved, but the size of opening pattern in mask becomes very small making it difficult to form the pattern
Solution Approach 1:
The pixel array is divided into multiple block regions, where each block contains multiple pixels. This segmentation allows the mask opening pattern to be formed in a modular manner, improving manufacturability while maintaining high resolution. The block structure enables easier formation of opening patterns compared to attempting to form all pixel openings simultaneously in a single large pattern.
2Measurement precision
If the distance between two adjacent pixels is made relatively short to increase resolution, then the resolution is improved, but the deposited organic light emitting material in one opening may invade another opening causing color mixing
Solution Approach 1:
The pixel defining layer is configured with different structures in different regions: in the first block region, the pixel defining layer has a first structure, and in the second block region, it has a second structure. This local differentiation allows optimization of material containment in each region, preventing color mixing while maintaining short pixel distances for high resolution. The pixel defining layer extends in the thickness direction to effectively contain the organic light emitting material within each pixel opening.
3Measurement precision
If the pixel size is reduced to achieve high resolution, then the resolution is improved, but the manufacturing yield of the mask is reduced
Solution Approach 1:
The mask opening pattern is segmented into multiple blocks, where each block contains multiple pixel openings. This segmentation improves manufacturing yield by allowing the mask to be manufactured in a modular fashion, reducing the complexity and difficulty of forming the entire pattern at once. The block structure enables better control over the formation process, thereby improving yield while maintaining high resolution.
4Ease of manufacture
If multiple organic light emitting materials are stacked in one opening, then the material deposition is simplified, but the colors of light mix causing poor color purity
Solution Approach 1:
The pixel defining layer is configured with different structures in different block regions to locally optimize material containment. The pixel defining layer extends in the thickness direction to effectively contain the organic light emitting material within each pixel opening, preventing lateral diffusion and color mixing. This structural differentiation maintains color purity while allowing for simplified deposition processes.
Data Source
AI summary
A display device, includes: a plurality of unit areas, each of the plurality of unit areas including a first border having a hexagonal shape including: a first outer side; and a second outer side parallel to the first outer side, and having a length equal to a length of the first outer side; a pixel area in each of the plurality of unit areas, and including a second border having a hexagonal shape including: a first inner side adjacent to the first outer side; and a second inner side adjacent to the second outer side; and first to fourth sub-pixel areas in the pixel area. The second outer side of one unit area from among two unit areas adjacent to each other in a column direction from among the plurality of unit areas contacts the first outer side of another unit area from among the two unit areas.