OLED Pixel Arrangement for Vaporization Mask Precision
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Solution Overview
Problem
The existing manufacturing processes for OLED display devices face challenges in increasing resolution while maintaining the minimum accuracy of vaporization openings, which are limited by the fine metal mask (FMM) technology used for evaporation of organic luminescent materials.
Innovation Solution
The OLED display device employs a configuration of five sub-pixels per pixel unit, with four corner sub-pixels of the same shape and size forming a regular pattern around a central sub-pixel, allowing for simultaneous vaporization of organic material light-emitting layers using a single vaporization opening, thereby reducing the complexity of manufacturing vaporization openings and improving resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional FMM technology is used for evaporation of organic luminescent materials, then manufacturing process is established, but manufacturing precision deteriorates due to difficulty in increasing resolution while maintaining minimum accuracy of vaporization openings
Solution Approach 1:
The pixel unit is divided into five sub-pixels (four corner sub-pixels and one central sub-pixel) with specific arrangement. The four corner sub-pixels are grouped together and can be vaporized through a single vaporization opening, effectively segmenting the vaporization process into manageable units that maintain precision while simplifying mask fabrication.
Solution Approach 2:
Multiple sub-pixels (specifically the four corner sub-pixels of the same color) are combined into a single vaporization region that can be covered by one vaporization opening. This merging approach allows simultaneous vaporization of multiple sub-pixels through a single mask opening, reducing the number of required vaporization openings and simplifying the FMM structure.
2Manufacturing precision
If number of vaporization openings is increased to achieve higher resolution, then resolution improves, but device complexity increases due to complexity of mask structure
Solution Approach 1:
A single vaporization opening serves multiple functions by enabling simultaneous vaporization of multiple corner sub-pixels of the same color across different pixel units. This multi-functional design reduces the total number of vaporization openings required while maintaining high resolution, thereby simplifying the overall mask structure.
Solution Approach 2:
The sub-pixel arrangement utilizes spatial dimensionality optimization where the five sub-pixels are positioned in a specific geometric pattern (four corners and one center). This dimensional arrangement allows overlapping vaporization regions to cover multiple sub-pixels efficiently, reducing the number of discrete vaporization openings needed while maintaining resolution.
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 configuration enables the reduction of processing difficulties for vaporization openings while maintaining the same resolution as traditional methods, allowing for improved resolution and guaranteed minimal accuracy in the manufacturing process.
Implementation Method 1
forming organic material light-emitting layers in regions of four sub-pixels at four corners and one sub-pixel surrounded by the four sub-pixels in each of the pixel units by vaporization
Data Source
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AI summary
An OLED display device and a manufacturing method thereof, a display device and a vaporization mask are disclosed. Five sub-pixels (101) in a pixel unit (10) of the display device includes at least one red, at least one green and at least one blue sub-pixel. Four of the five sub-pixels (101) are distributed at four corners and have the same shape and size, the other one is surrounded by the four sub-pixels (101), and the four sub-pixels (101) and the one sub-pixel (101) are of different colors. Any one sub-pixel (101) at a corner of the pixel unit (10) forms a regular pattern with one sub-pixel at a corner in each of other three adjacent pixel units (10), and in the regular pattern, all of the sub-pixels are of a same color and each occupies 1/4 of the pattern. The display device can reduce the difficulty of manufacturing vaporization openings of a mask and increase the display resolution.