Stacked Sub-Pixel Layers for High PPI Display Substrates
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Solution Overview
Problem
Current manufacturing processes struggle to increase pixels per inch (PPI) in high-resolution display panels due to difficulties in thinning TFT elements, metal traces, and other structures, limiting the development of high-resolution display panels.
Innovation Solution
A display substrate with two sub-pixel layers on opposite sides of a substrate, where the orthographic projections of the sub-pixels do not overlap, allowing for reduced pixel pitch without changing the pixel interval, thereby improving PPI.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the pixel interval is reduced to increase PPI, then the resolution is improved, but the manufacturing process becomes more difficult and complex
Solution Approach 1:
The patent transitions from a conventional single-layer pixel arrangement to a three-dimensional stacked architecture with first and second sub-pixel layers positioned on opposite sides of the substrate. This dimensional change allows pixels to be arranged in space without increasing planar density requirements, achieving higher PPI while maintaining manageable manufacturing processes.
Solution Approach 2:
The pixel array is segmented into two separate sub-pixel layers, each containing multiple sub-pixels. The first sub-pixel layer includes first sub-pixels with first pixel definition layers, and the second sub-pixel layer includes second sub-pixels with second pixel definition layers. This segmentation distributes the manufacturing complexity across two simpler layers rather than one highly dense layer.
2Measurement precision
If the pixel interval is reduced to increase PPI, then the resolution is improved, but the process requirements increase and become difficult to realize
Solution Approach 1:
By stacking sub-pixel layers in the vertical dimension rather than packing them closer in the planar dimension, the patent achieves reduced effective pixel interval without imposing stricter requirements on planar manufacturing precision. The orthographic projections of corresponding sub-pixels on the substrate do not overlap, enabling precise alignment through vertical stacking rather than lateral positioning.
Solution Approach 2:
The patent incorporates spacing regions between adjacent sub-pixels in each layer, with pixel definition layers that extend into these spacing regions. This beforehand cushioning provides manufacturing tolerance and alignment buffer zones, reducing the precision requirements for subsequent processing steps while maintaining the reduced pixel interval.
3Measurement precision
If the pixel interval is reduced to increase PPI, then the resolution is improved, but it is difficult to further increase PPI under current manufacturing capacity
Solution Approach 1:
The stacked sub-pixel layer architecture exploits the vertical dimension to increase PPI, effectively decoupling resolution improvement from planar manufacturing capacity constraints. This allows higher PPI to be achieved through vertical integration rather than lateral scaling, which is limited by current manufacturing throughput.
Solution Approach 2:
The patent merges multiple sub-pixels (first and second sub-pixel layers) into a single integrated display structure that functions as one coherent pixel unit. This combining approach increases the effective pixel count and PPI while maintaining manufacturing processes that operate within existing capacity limits, as each layer can be processed using standard techniques.
Data Source
AI summary
A display substrate includes a first substrate, a first sub-pixel layer and a second sub-pixel layer positioned on the first substrate; the first sub-pixel layer includes a plurality of first sub-pixels, the second sub-pixel layer includes a plurality of second sub-pixels, and a first orthographic projection of the first sub-pixel on the first substrate does not overlap with a second orthographic projection of the second sub-pixel on the first substrate. A display panel, a display device and a method for manufacturing the display substrate are also disclosed.