OLED Pixel Layout Structure for High-Resolution Metal Mask Evaporation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current high-precision metal masks used in OLED display technology face challenges in achieving high-resolution displays due to limitations in precision, leading to difficulties in fabricating pixel structures with satisfactory resolution.
Innovation Solution
A pixel layout structure comprising alternately arranged first, second, and third sub-pixels, with specific shapes and sizes, and a set of high-resolution metal masks with corresponding openings to facilitate even stress distribution and reduced pattern complexity during evaporation deposition, allowing for closer sub-pixel arrangement and increased area per sub-pixel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional high-precision metal masks are used for evaporation deposition, then the manufacturing process can be completed, but the display resolution is insufficient and pixel structure quality is poor
Solution Approach 1:
The pixel structure is divided into multiple sub-pixels (first sub-pixels, second sub-pixels, third sub-pixels) arranged in specific patterns. This segmentation allows each sub-pixel to be precisely controlled during evaporation deposition, improving overall pixel structure precision while enabling higher display resolution through the collective arrangement of multiple smaller units.
Solution Approach 2:
Different sub-pixel types (first, second, third sub-pixels) are assigned different positions and characteristics within the pixel structure. This local differentiation optimizes the evaporation deposition process for specific regions, achieving superior precision in critical areas while maintaining overall high-resolution display quality.
2Measurement precision
If sub-pixels are arranged closer together to increase resolution, then display resolution improves, but stress distribution during evaporation deposition becomes uneven and pattern complexity increases
Solution Approach 1:
The pixel layout employs asymmetric arrangements of different sub-pixel types (first, second, third sub-pixels) rather than uniform symmetric patterns. This asymmetric design reduces pattern complexity by breaking symmetry-induced manufacturing challenges, while still achieving close sub-pixel spacing for high resolution. The asymmetric layout facilitates more uniform stress distribution during evaporation deposition.
Solution Approach 2:
Instead of arranging identical sub-pixels in a uniform grid, the invention inverts the conventional approach by using alternating patterns of different sub-pixel types. This inverted strategy simplifies the overall pattern complexity while maintaining close spacing, as the alternating design creates more predictable stress distribution patterns during manufacturing.
3Ease of manufacture
If conventional pixel layouts are used, then manufacturing is straightforward, but opening ratios are low and display quality is limited
Solution Approach 1:
The invention transitions from conventional two-dimensional pixel arrangements to a more sophisticated multi-dimensional sub-pixel configuration. By organizing first, second, and third sub-pixels in alternating patterns across multiple dimensions, the design achieves higher opening ratios while maintaining manufacturing simplicity through systematic repetition of the sub-pixel units.
Solution Approach 2:
The alternating sub-pixel pattern serves multiple functions simultaneously: it increases opening ratios for better light output, maintains ease of manufacture through repetitive modular units, and enables high-resolution display. This universal design approach resolves the contradiction by making a single layout structure accomplish multiple performance goals.
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
The proposed solution enables a high-resolution display with reduced difficulty in evaporation deposition, extended display life, and minimized color mixing, while allowing for uniform stress distribution and increased opening ratios, thus improving the overall display quality.
Implementation Method 1
Each of the plurality of sub-pixels is generally an organic electroluminescent structure formed at each position of an array substrate corresponding to each of the plurality of sub-pixel through an evaporation filming of an organic material by means of a high-precision metal mask
Data Source
AI summary
A pixel layout structure includes a plurality of first sub-pixels, a plurality of second sub-pixels, and a plurality of third sub-pixel, which are arranged as a plurality of first repeat units, each including a first sub-pixel and a second sub-pixel, and further as a plurality of second repeat units, each including a third sub-pixel and a second sub-pixel. The first repeat units and the second repeat units are alternately arranged along a first direction and a second direction intersecting with it. The second sub-pixels are arranged in a matrix along the first direction and the second direction. Every four second sub-pixels surround one first sub-pixel or one third sub-pixel, and the first sub-pixels and the third sub-pixels are alternately arranged in the first direction and the second direction.