OLED Array Substrate Continuous Light-Emitting Layers
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Solution Overview
Problem
Current OLED display technologies face challenges in increasing Pixels Per Inch (PPI) and aperture ratio due to limitations in the precision of fine metal masks (FMMs) used in vacuum evaporation, leading to poor color mixing and reduced brightness and lifespan of OLED products.
Innovation Solution
The OLED array substrate design features pixel units with sub-pixels of different colors arranged in a specific pattern, allowing for the formation of light-emitting layer patterns through larger mask openings, reducing the gap between sub-pixels and improving PPI and aperture ratio without increasing fabrication complexity, and the manufacturing method involves using masks with specific openings to deposit light-emitting layers efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the opening size of the evaporation pattern of the FMM is reduced to improve PPI, then the resolution increases, but the fabrication precision of the FMM reaches the limit and manufacturing complexity increases
Solution Approach 1:
The patent segments the light-emitting layers of adjacent sub-pixels of the same color into a single continuous layer formed by one mask opening. This segmentation approach allows the mask opening to be larger while still achieving high PPI, as the continuous layer can be precisely controlled despite the larger opening size, thus resolving the contradiction between PPI improvement and FMM fabrication precision limits
Solution Approach 2:
The patent merges the light-emitting layers of multiple adjacent sub-pixels of the same color into a single continuous layer. By combining these layers and forming them through one mask opening rather than separate openings for each sub-pixel, the effective mask opening size increases, making fabrication feasible while maintaining high resolution through the continuous layer structure
2Measurement precision
If the distance between two sub-pixels is reduced to improve PPI, then the resolution increases, but light-emitting material shifts between sub-pixels causing poor color mixing
Solution Approach 1:
The patent segments sub-pixels of the same color across adjacent pixel units and forms their light-emitting layers as a single continuous structure. This segmentation strategy allows closer spacing between sub-pixels while maintaining color accuracy, as the continuous layer prevents material shift issues that would occur with separate, closely-spaced sub-pixel openings
Solution Approach 2:
The continuous light-emitting layer acts as an intermediary structure between adjacent sub-pixels of the same color. This continuous layer mediates the potential color mixing problems by providing a unified formation process that prevents material shift, while still allowing the sub-pixels to be closely spaced for high PPI
3Ease of manufacture
If traditional FMM vacuum evaporation is used to form light-emitting layers, then the process is established, but the aperture ratio is limited and manufacturing precision reaches the limit
Solution Approach 1:
The patent merges multiple light-emitting layer formations into a single evaporation process using one mask opening to create continuous layers. This merging approach increases the effective aperture ratio by reducing the number of separate mask openings needed, while maintaining the established vacuum evaporation manufacturing process
Solution Approach 2:
The patent changes the dimensional approach by forming continuous light-emitting layers that extend across multiple sub-pixels in a unified structure. This dimensional change from discrete sub-pixel layers to continuous表-subpixel layers allows larger effective aperture area while maintaining the same manufacturing process
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 enhances the resolution and aperture ratio of OLED displays, simplifies the manufacturing process, and improves brightness and lifespan while reducing costs and the incidence of poor color mixing.
Implementation Method 1
a film-forming technology of an organic light-emitting material is mainly in a mode of vacuum evaporation
Data Source
AI summary
Provided are an OLED array substrate and a manufacturing method thereof, and a display device. The OLED array substrate includes a substrate and a plurality of pixel units provided thereon. The plurality of pixel units are arranged into a plurality of rows extending in a first direction and a plurality of columns extending in a second direction. Each pixel unit includes a plurality of subpixels emitting light of different colors. At least two subpixels emitting light of the same color are adjacent to each other in at least one of the first direction and the second direction.