Mask Opening Pattern Distance Adjustment for 8K Display Panels
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Solution Overview
Problem
Conventional 8K electronic equipment requires masks of different sizes for display panels of varying sizes, leading to increased manufacturing costs and complexity.
Innovation Solution
A mask design with a substrate and opening pattern featuring repeat regions with specific side regions, allowing for the same mask size to be used across different display panel sizes by adjusting distances between the opening pattern and the edges, utilizing diffraction effects to achieve the required pixel sizes without changing the opening pattern size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If masks of different sizes are manufactured for display panels of different sizes, then the manufacturing precision of pixel sizes is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies universality by designing a single mask size that can be used for multiple display panel sizes (e.g., 65-inch and 85-inch 8K panels). The mask includes a repeat region with an opening pattern and side regions that can be selectively used depending on the target display panel size, allowing one mask to serve multiple functions and eliminating the need for separate masks for different panel dimensions.
Solution Approach 2:
The mask is segmented into functional regions: a repeat region containing the opening pattern for forming pixel regions, and side regions (first and second side regions) that can be selectively engaged. This segmentation allows the mask to be used in different configurations for different display panel sizes while maintaining a single physical mask structure.
2Manufacturing precision
If masks of different sizes are manufactured for display panels of different sizes, then the manufacturing precision of pixel sizes is improved, but the manufacturing cost increases
Solution Approach 1:
By making the mask universal across different display panel sizes, the patent eliminates the need to manufacture multiple separate masks. The single mask design with configurable side regions reduces development costs, manufacturing costs, and inventory costs associated with maintaining multiple mask sizes, while still achieving the required pixel size precision for different panel dimensions.
3Device complexity
If the opening pattern size is kept constant, then the device complexity is reduced, but the manufacturing precision of different pixel sizes deteriorates
Solution Approach 1:
The patent employs asymmetry in the distance relationships within the repeat region. The first distance (from the opening pattern to the first side region) is intentionally different from the second distance (from the opening pattern to the second side region). This asymmetric design allows the same opening pattern to produce different effective pixel sizes by selectively engaging different side regions, thereby maintaining device simplicity while achieving manufacturing precision for different panel sizes.
Solution Approach 2:
The patent changes geometric parameters (distances between the opening pattern and side regions) rather than changing the opening pattern itself. By varying the first distance and second distance parameters, the same opening pattern can accommodate different display panel sizes and pixel density requirements, maintaining pattern consistency while achieving size adaptation through parameter adjustment.
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 solution enables the use of the same mask size for display panels with the same resolution but different sizes, reducing manufacturing costs and complexity by varying the distances between the opening patterns and the edges, thus addressing the need for multiple mask sizes.
Implementation Method 1
utilizing diffraction effects to achieve the required pixel sizes without changing the opening pattern size
Data Source
AI summary
A mask, a display panel, and an electronic equipment are provided. The mask allows an opening pattern to be moved to a side of a repeat region. Based on this structure, the display panels with the same resolution and different sizes may use the masks with the same size, and differences between these masks are merely different distances between the opening patterns and edges of the repeat regions, thus solving at least one technical problem existing in conventional 8K electronic equipment that the masks with the different sizes require to be manufactured for the display panels with the different sizes.