Hexagonal Pixel Arrangement for High-Precision Metal Mask Vapor Deposition
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Solution Overview
Problem
The manufacturing process for high-resolution OLED display apparatuses is limited by the difficulty in producing high-precision metal masks, which restricts the size and arrangement of sub-pixels, making it challenging to achieve high-resolution displays using conventional RGB pixel arrangements.
Innovation Solution
A pixel arrangement structure featuring a virtual hexagon pattern with a first sub-pixel at the center and second and third sub-pixels alternately arranged at the vertices, sharing common sides, allowing for closer sub-pixel placement and increased area, along with a high-precision metal mask design with evenly distributed opening regions to facilitate vapor deposition and reduce stress concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional RGB pixel arrangement structure is used, then manufacturing process is simple, but manufacturing precision of high-resolution display is limited due to difficulty in producing high-precision metal masks
Solution Approach 1:
The pixel arrangement is segmented into multiple types (first, second, third, and fourth sub-pixels) with different configurations. Each sub-pixel type has specific opening size and position characteristics, allowing the metal mask to be divided into multiple regions with different precision requirements, thereby reducing overall manufacturing difficulty while maintaining high display resolution.
Solution Approach 2:
The patent transitions from conventional planar pixel arrangements to a three-dimensional stacked structure where sub-pixels are arranged at different heights and positions. This dimensional change allows for more efficient use of space and reduces the precision requirements for metal mask openings in any single plane, enabling high-resolution displays with more manageable manufacturing complexity.
2Area of moving object
If sub-pixel size is increased to improve display area, then area of moving object increases, but minimum distance between sub-pixels increases reducing display resolution
Solution Approach 1:
Sub-pixels are arranged in three-dimensional space with different vertical positions and horizontal offsets. This allows sub-pixels to be physically larger while maintaining small horizontal pitch through vertical stacking, effectively decoupling sub-pixel area from pixel pitch and enabling both large sub-pixel areas and high display resolution simultaneously.
Solution Approach 2:
Multiple sub-pixel types are nested within a compact repeating unit structure. The first, second, third, and fourth sub-pixels are arranged in a nested configuration where smaller sub-pixels fill spaces between larger ones, maximizing the use of available area while maintaining small overall unit dimensions for high-resolution displays.
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 configuration enables high-resolution display effects with reduced driving current and extended device lifetime by allowing for closer sub-pixel arrangement and uniform stress distribution during vapor deposition.
Implementation Method 1
formed by an evaporation film-forming technique using a high-precision metal mask
Data Source
AI summary
A pixel arrangement structure may include a plurality of repeating units (100). Each of the plurality of the repeating units (100) may include a first sub-pixel (01) being at a center point of a virtual hexagon and second sub-pixels (02) and third sub-pixels (03) being alternately arranged at vertices of the virtual hexagon. Virtual hexagons of adjacent repeating units may share one common side as well as two sub-pixels on the common side.