OLED Display Substrate Pixel Arrangement and Fine Metal Mask
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Solution Overview
Problem
Current OLED display production processes face challenges in achieving high resolution while minimizing production complexity and cost, particularly due to inaccurate pixel arrangement designs that result in suboptimal opening rates and inefficient use of space, leading to potential defects like color cast and reduced service life.
Innovation Solution
A display substrate and fine metal mask set are designed with a specific arrangement of sub-pixels, including a first-color, second-color, and third-color sub-pixels, where the second-color sub-pixels are paired and arranged to maximize light-emitting area, and the fine metal masks are configured to form connected light-emitting layers with optimized spacing, enhancing the opening rate and reducing production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If traditional fine metal mask arrangements are used, then manufacturing process is simpler, but light-emitting area is reduced and opening rate is suboptimal
Solution Approach 1:
The pixel arrangement is segmented into repeat units, each containing one first-color sub-pixel, one second-color sub-pixel pair, and one third-color sub-pixel. This segmentation allows for systematic optimization of light-emitting areas while maintaining manufacturability through modular repetition across the display substrate.
Solution Approach 2:
The second-color sub-pixels are arranged in pairs along a second direction perpendicular to the first direction, creating a two-dimensional optimization strategy. This dimensional approach maximizes light-emitting area by utilizing both horizontal and vertical space efficiently within each repeat unit.
2Measurement precision
If sub-pixel density is increased for high resolution, then display resolution is improved, but production complexity and cost increase
Solution Approach 1:
The virtual pixel method allows certain sub-pixels to serve multiple functions by being shared between adjacent pixels. For example, a sub-pixel can contribute to both its home pixel and neighboring pixels, reducing the total number of sub-pixels needed while maintaining high display resolution.
Solution Approach 2:
The invention changes the arrangement parameters of sub-pixels by introducing paired second-color sub-pixels and optimizing their positions relative to other color sub-pixels. This parameter optimization achieves high resolution displays with reduced sub-pixel density compared to traditional one-to-one pixel mappings.
3Productivity
If light-emitting layers of adjacent sub-pixels are connected, then opening rate is improved, but color cast defects may occur
Solution Approach 1:
The patent applies different connection strategies to different color sub-pixels based on their specific positions and functions. Light-emitting layers are connected where it benefits opening rate, while appropriate spacing is maintained in regions where color separation is critical to prevent color cast defects.
Solution Approach 2:
Instead of universally connecting all adjacent light-emitting layers, the invention selectively connects only certain pairs based on their functional requirements. This partial connection approach achieves sufficient opening rate improvement without excessive connection that would cause color mixing defects.
4Reliability
If spacing is increased between light-emitting layers, then color cast is reduced, but opening rate decreases
Solution Approach 1:
The patent implements spacing between light-emitting layers only where necessary to prevent color cast, rather than applying uniform spacing across all sub-pixels. This partial spacing strategy maintains color accuracy in critical regions while preserving opening rate in regions where connection is beneficial.
Data Source
AI summary
A display substrate, a fine metal mask set and a manufacturing method thereof are provided. The display substrate includes a plurality of repeat units. Each of the plurality of repeat units includes one first-color sub-pixel, one second-color sub-pixel pair and one third-color sub-pixel which are arranged in a first direction, the second-color sub-pixel pair includes two second-color sub-pixels arranging in a second direction. Light-emitting layers of adjacent sub-pixels of two different colors in the first direction are connected with each other; light-emitting layers of the third-color sub-pixel and the second-color sub-pixel which are adjacent to each other in the second direction are connected with each other; and a spacing is disposed between the light-emitting layer of the first-color sub-pixel and the light-emitting layer of at least one of the second-color sub-pixel and the third-color sub-pixel which are adjacent to the first-color sub-pixel in the second direction.