Pixel Islands and Microlens Layer for High PPI OLED Displays
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Solution Overview
Problem
Current OLED display technologies face limitations in achieving high PPI due to challenges in the layout design of pixel driving circuits and the manufacturing of fine metal masks, which restrict the resolution and light utilization of high PPI displays.
Innovation Solution
A display panel design featuring a base substrate with a pixel layer comprising pixel islands and a microlens layer, where sub-pixels of the same color are co-evaporated through a mask and their light is refracted by the microlens layer to be dispersed or converged to different pixel areas, allowing for high PPI displays using masks with fewer openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional LCD or OLED display structures are used with conventional pixel layouts, then the display can be manufactured with standard processes, but the PPI (pixels per inch) is limited and resolution cannot be significantly improved
Solution Approach 1:
The display is divided into multiple sub-pixel regions (first sub-pixel region, second sub-pixel region, third sub-pixel region) within each pixel unit. Each sub-pixel region contains multiple sub-pixels that can be independently controlled, effectively segmenting the pixel structure to achieve higher PPI without proportionally increasing driving circuit complexity
Solution Approach 2:
Multiple sub-pixels within each sub-pixel region share common driving circuit elements (such as transistors and capacitors), allowing a single driving circuit to control multiple sub-pixels. This multi-functionality reduces the overall number of driving circuit elements needed while maintaining high PPI
2Measurement precision
If high PPI is achieved through conventional methods, then resolution improves, but the manufacturing complexity of fine metal masks increases significantly
Solution Approach 1:
The mask structure is segmented into multiple regions corresponding to different sub-pixel groups. Each mask region can be manufactured with relaxed precision requirements compared to a single fine mask, as the segmentation allows for separate manufacturing and assembly of mask portions
Solution Approach 2:
A color conversion layer is introduced as an intermediary between the light source and the mask structure. This layer converts light wavelengths and enables the mask to work with larger feature sizes, reducing the need for extremely fine mask features while maintaining high resolution
3Measurement precision
If more sub-pixels are packed into each pixel unit, then PPI increases, but light utilization efficiency decreases due to increased structural complexity
Solution Approach 1:
Multiple sub-pixels that emit the same or complementary colors are merged into a single pixel unit and share common driving circuitry and color conversion elements. This merging reduces redundant structures and improves light utilization efficiency while maintaining high PPI
Solution Approach 2:
The patent utilizes color conversion layers that can convert light wavelengths to produce different colors. By using color conversion rather than requiring separate colored sub-pixels for each wavelength, the structure reduces material usage and improves light efficiency while achieving high color accuracy and PPI
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 enables the manufacture of high PPI displays with improved light transmittance and utilization, reducing the complexity of mask manufacturing and evaporation processes, while achieving high resolution and efficient light use compared to traditional methods.
Implementation Method 1
the light emitted by the plurality of sub-pixels in each of the pixel islands is refracted by the microlens layer to be dispersed to different pixel areas
Data Source
AI summary
The present application relates to the field of display technology, and in particular, to a display panel, method for manufacturing a display panel and display device. The display panel includes: a base substrate; a pixel layer, provided on the base substrate and comprising a plurality of pixel islands; and a microlens layer, provided on a surface of the pixel layer facing away from the base substrate. Each of pixel islands includes a plurality of sub-pixels that emit light of a same color and are seamlessly coupled to each other, and the light emitted by the plurality of sub-pixels in each of the pixel islands is refracted by the microlens layer to be dispersed to different pixel areas.