Staggered OLED Sub-pixel Mask Design for Fabrication Stability
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Solution Overview
Problem
High-resolution OLED display devices face challenges in maintaining mechanical stability of fine masks during fabrication, leading to cross-contamination of organic light emitting materials and reduced product yield due to susceptibility to deformation.
Innovation Solution
A new pixel arrangement mode with staggered sub-pixels and a modified mask design featuring a metal bridge and larger openings to enhance mask stability and prevent color mixing, allowing for improved resolution and production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fine mask with small openings is used to achieve high resolution, then the resolution improves, but the mechanical stability of the mask deteriorates due to susceptibility to deformation
Solution Approach 1:
The mask structure is segmented into multiple independent components: a rigid support substrate and separate opening regions formed by removing material. This segmentation allows the openings to be small for high resolution while the support substrate maintains mechanical stability.
Solution Approach 2:
The mask employs a composite structure combining a rigid support substrate (providing mechanical stability) with opening regions (enabling high resolution). This composite design resolves the contradiction by integrating materials with complementary properties - the rigid substrate prevents deformation while the removed material creates precise small openings for high-resolution patterning.
2Stability of the object's composition
If the mask structure is made more rigid to improve mechanical stability, then the mask stability improves, but the aperture ratio deteriorates due to larger supporting structures
Solution Approach 1:
The mask is segmented into a minimal support framework and discrete opening regions. This segmentation allows the support structure to be sufficiently rigid for mechanical stability while occupying minimal area, thereby maintaining a high aperture ratio for efficient light transmission and material deposition.
Solution Approach 2:
The composite mask design uses a rigid support substrate that provides mechanical stability with minimal material volume. The opening regions are precisely defined by material removal rather than added structures, ensuring that the rigid support does not excessively reduce the aperture ratio.
3Ease of manufacture
If traditional pixel arrangement is used, then the fabrication process is simple, but cross-contamination occurs due to mask deformation
Solution Approach 1:
The mask design segments the opening regions spatially with sufficient separation, preventing material deposited for one sub-pixel from contaminating adjacent sub-pixels. This segmentation maintains fabrication simplicity while eliminating cross-contamination issues that arise from mask deformation in traditional designs.
Data Source
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AI summary
An organic light emitting diode display device and a display apparatus, and a mask for fabricating a sub-pixel of the organic light emitting diode display device are provided. Each pixel unit group (11) includes a first sub-pixel unit group (111) and a second sub-pixel unit group (112) which are disposed adjacently along a first direction and include three sub-pixels of different colors, respectively; and the three sub-pixels in the first sub-pixel unit group (111) and the three sub-pixels in the second sub-pixel unit group (112) are staggered along a second direction, and a color of any sub-pixel on a base substrate 10 is different from a color of any other sub-pixel adjacent to the sub-pixel. The organic light emitting diode display device ensures that the sub-pixels of a same color are staggered regularly on the base substrate, which increases strength of the mask, and is conducive to fabrication of the sub-pixel of a small size, so that the resolution of the organic light emitting diode display device can be improved.