OLED Hexagonal Pixel Arrangement for Mask Fabrication
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Solution Overview
Problem
The existing OLED display technology faces challenges in achieving higher resolution and reducing production costs due to the complexity of mask fabrication and color mixing issues in the vapor deposition process, which limits the improvement of OLED resolution.
Innovation Solution
The OLED display device employs a pixel arrangement where first and second pixel units, each with a hexagonal shape and comprising sub-pixels of identical pentagonal shape, are alternately arranged to form a hexagon, allowing for larger mask openings and reduced fabrication complexity, thereby improving alignment and suppressing color mixing during vapor deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a highly accurate alignment system and highly precise photomask are used in the existing fabrication process, then the pixel deposition precision is improved, but the mask fabrication complexity increases and color mixing issues occur during vapor deposition
Solution Approach 1:
The pixel is divided into multiple sub-pixels with different colors (RGBW) arranged in a specific pattern. Each sub-pixel is deposited through separate mask openings, allowing independent control of each color layer and reducing the complexity of the overall mask fabrication process while maintaining high deposition precision
Solution Approach 2:
The patent transitions from a traditional single-color pixel arrangement to a multi-color sub-pixel arrangement within the same pixel area. By organizing RGBW sub-pixels in a specific spatial configuration, the patent achieves higher resolution without increasing mask complexity, as the same mask structure can accommodate all color sub-pixels
2Measurement precision
If the resolution of the display panel is increased, then the display quality is improved, but the mask fabrication becomes more complicated and approaches the physical limit
Solution Approach 1:
Multiple color sub-pixels (RGBW) are merged into a single pixel unit with a unified mask structure. This merging approach allows the fabrication process to treat multiple colors simultaneously through one mask, reducing the number of separate mask fabrication steps required while achieving high resolution through the multi-color sub-pixel arrangement
3Ease of manufacture
If traditional vapor deposition process is used with existing mask structures, then the deposition process is simple, but color mixing and misalignment issues occur
Solution Approach 1:
Each sub-pixel is designed with specific local characteristics, including dedicated mask openings and defined geometric shapes (pentagons forming hexagons). This local quality differentiation allows precise control of material deposition in each sub-pixel region, preventing color mixing while maintaining the simplicity of the vapor deposition process
Solution Approach 2:
The patent introduces an intermediary pixel defining structure with specific geometric shapes (pentagonal sub-pixels forming hexagonal pixels) that acts as a mediator between the mask and the deposition process. This intermediary structure guides the vapor deposition to prevent misalignment and color mixing while maintaining process simplicity
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 approach reduces the complexity of mask fabrication and minimizes color mixing, leading to enhanced display panel resolution and lower power consumption while maintaining or improving the lifespan of OLED display panels.
Implementation Method 1
An organic light-emitting display device adopts OLEDs to display images, in which an OLED is a self-luminous device
Data Source
AI summary
An OLED display device is provided. The OLED display device comprises first pixel rows and second pixel rows. A first pixel row includes first and second pixel units, and a second pixel row includes third and fourth pixel units. A first, a second, a third, and a fourth pixel units have an identical hexagonal shape, and each includes a first, a second, a third, and a fourth sub-pixels, each of which has an identical pentagonal shape. The first sub-pixel in the first pixel unit, the second sub-pixel in the second pixel unit adjacent to the first pixel unit, the third sub-pixel unit in the third pixel unit adjacent to both the first pixel unit and the second pixel unit, and the fourth sub-pixel unit in the fourth pixel unit adjacent to both the first pixel unit and the second pixel unit have a same color and together form a hexagon.