OLED Pixel Arrangement for High Resolution via Mask Reuse
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Solution Overview
Problem
The limitation of manufacturing accuracy in fine metal masks (FMMs) restricts the reduction in size of openings, thereby limiting the improvement of OLED display device resolution.
Innovation Solution
A pixel arrangement structure with sub-pixels arranged in rows and columns, where sub-pixel groups of different colors are staggered to allow multiple sub-pixels to be formed using a single larger opening on a mask, increasing the number of sub-pixels and improving resolution without the need for smaller mask openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the size of openings in FMM is reduced to improve resolution, then the resolution of OLED display device is improved, but the manufacturing accuracy requirement becomes unattainable
Solution Approach 1:
The patent divides a single pixel into multiple sub-pixels (e.g., first sub-pixel, second sub-pixel, third sub-pixel) that can be formed through separate evaporation processes. This segmentation allows each sub-pixel to be formed with larger, more manufacturable opening sizes while collectively achieving high resolution through precise spatial arrangement of the subdivided elements.
Solution Approach 2:
The patent introduces a temporal dimension to the manufacturing process by forming different sub-pixels in different evaporation steps through the same FMM opening. This multi-step evaporation approach transforms a single spatial constraint into a multi-temporal process, allowing high resolution to be achieved through sequential deposition rather than requiring extremely small simultaneous openings.
2Ease of manufacture
If the opening size on FMM is kept large for ease of manufacture, then the manufacturing complexity is reduced, but the number of sub-pixels that can be formed is limited
Solution Approach 1:
The patent performs preliminary actions by forming different sub-pixels in sequential evaporation steps through the same FMM opening. The first sub-pixel is formed in a first evaporation step, the second sub-pixel in a second evaporation step, and so on. This preliminary sequential formation allows a single large opening to serve multiple purposes across different time steps, increasing sub-pixel count without reducing opening size.
Solution Approach 2:
The FMM is reused across multiple evaporation steps for different sub-pixels. After forming one sub-pixel through an opening, the same FMM and opening are used to form additional sub-pixels in subsequent steps. This recovery and reuse of the same manufacturing aperture maximizes the utility of each opening, allowing more sub-pixels to be formed without requiring proportionally more or smaller openings.
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 allows for the formation of multiple sub-pixels through one opening, enhancing the resolution of OLED display devices while reducing the complexity and cost of the manufacturing process.
Implementation Method 1
a light emitting layer of an OLED device may be formed through an evaporation process by using a mask
Data Source
AI summary
A pixel arrangement structure, a display panel, a mask component, and an evaporation apparatus are provided. The pixel arrangement structure includes a plurality of sub-pixels arranged in a row direction and a column direction. The plurality of sub-pixels are divided into a plurality of rows of sub-pixel groups. Each of rows of sub-pixel groups include at least two rows of the sub-pixels, and include a plurality of repeating units arranged in sequence, and each of the repeating units includes at least two sub-pixel groups of different colors. Each of the sub-pixel groups includes at least two sub-pixels of a same color that are located in at least two rows and are adjacently arranged, and sub-pixels adjacent to each other and having different colors, which are located in sub-pixel groups of different colors, constitute one pixel.