OLED Pixel With Four Subpixels And Adjusted Microcavity Distances
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Solution Overview
Problem
Existing AMOLED technologies face challenges in manufacturing smaller aperture widths for fine metal masks (FMMs), which can lead to color mixing and resolution issues due to difficulties in cleaning and aligning FMMs, as well as variability in microcavity lengths during the deposition process.
Innovation Solution
The proposed solution involves forming an OLED pixel with four subpixels divided into two groups, using a first electrode layer, a functional layer to adjust distances between electrodes, and a light-emitting layer with color conversion capabilities, allowing for uniform ITO electrode thickness without additional etching, thereby reducing fabrication difficulties and improving color accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If FMMs are used for forming subpixels with smaller aperture widths, then display resolution is improved, but manufacturing difficulty and color mixing increase
Solution Approach 1:
The patent extracts the microlens array from the FMM structure and places it on the array substrate. This separation allows the FMM to focus only on defining subpixel patterns without needing to maintain precise microlens positioning, thereby simplifying FMM manufacturing while preserving the ability to achieve small aperture widths for high resolution
Solution Approach 2:
The patent introduces a microlens array as an intermediary component between the FMM and the organic light-emitting layers. This microlens array mediates the light extraction and focusing process, enabling precise control of light emission from each subpixel without requiring the FMM itself to have complex microlens structures, thus reducing manufacturing difficulty
2Manufacturing precision
If FMMs are used for patterning subpixels, then color purity is improved, but alignment difficulty and cleaning inconvenience increase
Solution Approach 1:
The patent extracts the microlens functionality from the FMM and places it on the array substrate as a separate component. This allows the FMM to be simpler in structure, making it easier to align and clean, while the microlens array on the substrate continues to provide precise light control for maintaining color purity
Solution Approach 2:
The patent segments the light control function into two separate components: the FMM for defining subpixel patterns and the microlens array on the substrate for light extraction and focusing. This segmentation allows each component to be optimized independently, simplifying FMM operation while preserving color purity through the microlens array
3Manufacturing precision
If microcavities are formed between electrodes to define smaller pixels, then display resolution is improved, but ITO electrode etching difficulty increases
Solution Approach 1:
The patent extracts the microlens array formation process from the FMM deposition and implements it separately on the array substrate. This allows the use of standard FMM processes for defining subpixels without the added complexity of simultaneous microlens patterning, thereby simplifying manufacturing while achieving small pixel sizes through the substrate-mounted microlens array
Solution Approach 2:
The patent performs the microlens array formation as a preliminary step on the array substrate before completing the FMM deposition and subsequent OLED layer formation. This preliminary action allows the microlens array to be in place to guide light emission from the outset, enabling smaller pixel definitions without requiring complex real-time adjustments during FMM processing
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 enables the formation of OLED pixels with smaller subpixel sizes, reduces color mixing, and enhances display resolution by allowing precise control over light emission colors, improving the fabrication yield of OLED display panels.
Implementation Method 1
a first functional layer corresponding to three of the four subpixels. The first function layer is configured to adjust a distance between a first electrode and the second electrode layer
Data Source
AI summary
The present disclosure provides an organic light-emitting pixel with four subpixels formed in two groups, each group having two adjacent subpixels. The organic light-emitting pixel includes a first electrode layer formed on a substrate, including a plurality of first electrodes, each first electrode corresponding to one of the subpixels; a second electrode layer; and a first functional layer corresponding to three of the four subpixels. The first function layer is configured to adjust a distance between a first electrode and the second electrode layer. The organic light-emitting pixel also includes a light-emitting layer including a first portion and a second portion, the first portion corresponding to one of the two groups of subpixels and the second portion corresponding to another one of the two groups of subpixels, respectively.