OLED Pixel Structure for High Resolution via Segmented Sub-pixels
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Solution Overview
Problem
Current OLED manufacturing processes limit the resolution of OLED panels due to the inability to effectively reduce the area of openings in shadow masks for organic electro-luminescent material evaporation, resulting in sub-pixel size constraints that hinder display resolution.
Innovation Solution
The method involves categorizing deposited regions on a substrate into groups of sub-pixels of the same color, allowing organic EL material to be evaporated through a single opening for multiple sub-pixels, thereby reducing sub-pixel area and enhancing panel resolution without altering the existing manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the opening area on the shadow mask for EL material evaporation is reduced to improve resolution, then the sub-pixel area can be reduced, but the manufacturing process becomes more difficult and the opening area cannot be effectively reduced due to process limitations
Solution Approach 1:
The patent divides a single sub-pixel into multiple sub-regions (first sub-region and second sub-region) that can be independently addressed. This segmentation allows the shadow mask opening to serve multiple purposes, effectively reducing the required opening area while maintaining manufacturability. Each sub-region can be controlled separately through different transistor circuits, enabling high resolution without requiring proportionally smaller opening areas.
Solution Approach 2:
The patent merges the function of a single shadow mask opening to deposit material for multiple sub-regions. Instead of requiring separate openings for each sub-region, one opening serves multiple purposes by depositing material that is subsequently divided into distinct sub-regions through patterned electrodes and transistor control. This merging approach maintains ease of manufacture while achieving higher resolution.
2Manufacturing precision
If the sub-pixel area is reduced to improve resolution, then more sub-pixels can fit on the panel, but the opening area on the shadow mask cannot be reduced sufficiently to achieve the desired resolution
Solution Approach 1:
Each sub-pixel is segmented into multiple sub-regions (first and second sub-regions) that share a common shadow mask opening. This segmentation allows the opening area to remain relatively large while still achieving high resolution, as one opening serves multiple sub-regions. The sub-regions are distinguished through patterned electrodes and independent transistor control rather than requiring proportionally smaller opening areas.
Solution Approach 2:
The shadow mask opening is given multi-functionality by using it to deposit material for multiple sub-regions. Instead of each opening serving only one sub-pixel, a single opening serves multiple sub-regions within a sub-pixel, reducing the total number of openings required and maintaining larger opening areas for ease of manufacture while achieving high resolution.
3Manufacturing precision
If multiple sub-pixels share the same evaporated material through a single opening, then the sub-pixel area is reduced and resolution is enhanced, but the manufacturing process complexity increases
Solution Approach 1:
The patent segments each sub-pixel into multiple sub-regions with independent transistor control circuits. While this increases device complexity, it enables the sharing of shadow mask openings among multiple sub-regions, reducing the opening area requirements and enhancing resolution. The segmentation is achieved through dividing the electrode into first and second electrodes, each controlled by separate transistors, allowing independent addressing of each sub-region.
Solution Approach 2:
The patent merges the material deposition function for multiple sub-regions into a single shadow mask opening, reducing manufacturing complexity related to opening fabrication. However, it increases device complexity by requiring multiple transistors and control circuits per sub-pixel to independently address each sub-region. The net effect is a trade-off that favors resolution enhancement while keeping the shadow mask fabrication relatively simple.
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 effectively improves OLED panel resolution by allowing multiple sub-pixels to share the same evaporated material, reducing sub-pixel area, and providing flexibility in sub-pixel design to enhance durability and display quality.
Implementation Method 1
The organic EL material is heated up and evaporated through an opening of a shadow mask onto a plurality of deposited regions on a substrate
Implementation Method 2
evaporated through an opening of a shadow mask onto a plurality of deposited regions on a substrate
Data Source
AI summary
An organic light emitting display (OLED) pixel structure is provided to improve the resolution of an OLED without significantly changing the current OLED manufacturing process. With a novel pixel arrangement and circuit layout, an organic light emitting material is evaporated onto a substrate through a mask and thus a plurality of sub-pixels are formed simultaneously while enabling each sub-pixel to correspond to different pixels. Therefore, the area of each sub-pixel is reduced and the resolution of a display is increased.