Staggered Pixel Unit Groups for High PPI Mask Design
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Solution Overview
Problem
Current display technologies face challenges in manufacturing high PPI (pixels per inch) display devices with uniformity due to limitations in the fine metal mask evaporation process, which restricts the size of mask openings and increases costs and process time.
Innovation Solution
A pixel display module with array-distributed pixel unit groups, where two sub-pixels on one diagonal emit the same color light and two on another diagonal emit different color lights, staggered in position to improve uniformity, and a mask design with open areas for adjacent sub-pixels sharing the same color light to reduce manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the fine metal mask evaporation process is used to manufacture OLED, then the display resolution can be improved, but the mask opening size is limited and cannot be made smaller
Solution Approach 1:
The patent segments the pixel structure into pixel unit groups, where each group contains multiple sub-pixels arranged in a specific pattern. This segmentation allows the mask opening to serve multiple sub-pixels simultaneously, effectively reducing the required mask opening size while maintaining high display resolution.
Solution Approach 2:
The patent merges the function of multiple mask openings into a single shared opening. By designing pixel unit groups where adjacent sub-pixels share common mask openings, the system reduces the number of required mask openings and their individual sizes, thereby improving manufacturability while achieving high PPI.
2Quantity of substance
If two or more masks are used in the evaporation process to achieve high PPI, then the display density can be improved, but the manufacturing cost and process time increase
Solution Approach 1:
The patent designs a single mask that performs multiple functions by creating shared openings that define multiple sub-pixels. This universal mask design eliminates the need for multiple sequential masks, reducing both process time and manufacturing complexity while achieving high display density.
Solution Approach 2:
The patent transitions from a conventional one-to-one mask opening-to-sub-pixel mapping to a many-to-one relationship where a single mask opening serves multiple sub-pixels. This dimensional change in the masking approach enables high PPI achievement with fewer masks and reduced process steps.
3Reliability
If sufficient space is maintained between adjacent pixels to avoid overlapping, then the manufacturing reliability is improved, but the pixel size increases and PPI decreases
Solution Approach 1:
The patent employs asymmetric pixel arrangements within pixel unit groups, where sub-pixels are positioned diagonally and share mask openings. This asymmetric design allows adjacent pixels to be closer without overlapping, reducing pixel size and increasing PPI while maintaining manufacturing reliability through the staggered configuration.
Data Source
AI summary
The embodiments of the present application provide a pixel display module. The pixel display module includes: a plurality of array-distributed pixel unit groups. Each of the pixel unit groups comprises four array-distributed sub-pixels, two of the sub-pixels located on a diagonal of each of the pixel unit groups emit a same first color light, and the other two of sub-pixels located on another diagonal of each of the pixel unit groups respectively emit a second color light and a third color light. Two pixel unit groups adjacent in a first direction are staggered along a second direction, and the second direction is perpendicular to the first direction.