Variable Sub-Pixel Spacing for Display Yield and Image Quality
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Solution Overview
Problem
The increasing density of sub-pixel Light Emitting Diode (LED) devices in display modules leads to a decrease in production yield due to the deep-submicron process challenges, and there is a need for a manufacturing method that enhances yield while minimizing image distortion.
Innovation Solution
The method involves varying the distance between sub-pixels within a pixel in a display device, with specific sub-pixel spacings in different pixels to maintain uniformity and reduce distortion, allowing for flexible adjustment of sub-pixel intervals to improve production yield and image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the interval between sub-pixels is reduced to increase integration density, then the resolution and screen size are improved, but the production yield decreases due to deep-submicron process challenges
Solution Approach 1:
The patent applies local quality by setting different sub-pixel intervals for different pixels on the substrate. Specifically, pixels at different locations (e.g., first region vs. second region) have different intervals between their sub-pixels. This allows the display device to achieve high resolution in certain areas while maintaining larger, more manufacturable intervals in other areas, thereby improving production yield without sacrificing overall display quality.
2Quantity of substance
If the sub-pixel interval is uniformly reduced across all pixels, then the integration density increases, but image distortion and border line occurrence increase
Solution Approach 1:
The patent implements local quality by varying the sub-pixel interval according to pixel location. Different regions of the substrate have different sub-pixel intervals, allowing high integration density in specific areas while maintaining image quality in other areas. This prevents uniform reduction from causing distortion and border lines.
Solution Approach 2:
The patent applies dynamics by making the sub-pixel interval variable rather than fixed. The interval changes dynamically based on the pixel's location on the substrate, allowing the system to adapt to different manufacturing and display requirements across different regions, thereby maintaining image quality while increasing integration density.
Data Source
AI summary
A display device includes a plurality of pixels. Each of the plurality of pixels includes a first, a second, and a third sub pixel that are disposed in a vertical direction. A first pixel of the plurality of pixels includes: a first sub pixel of the first pixel, a second sub pixel of the first pixel, which is disposed to be spaced apart from the first sub pixel of the first pixel by a first distance, and a third sub pixel of the first pixel, which is disposed to be spaced apart from the second sub pixel of the first pixel by the first distance. A second pixel of the plurality of pixels also includes a first sub pixel and a second sub pixel, which are separated apart by a second distance that is different from the first distance.