Method for manufacturing a display device

Abstract

A method for manufacturing a display device comprises: forming a light-emitting element array including a plurality of light-emitting elements on a substrate having a plurality of sub-pixels defined thereon, wherein each sub-pixel includes one of the light-emitting elements, and every four sub-pixels constitute a large sub-pixel, wherein the four sub-pixels of each large sub-pixel are located in two adjacent rows and two adjacent columns, and the four light-emitting elements of the same large sub-pixel are arranged to emit the same luminous color; detecting whether each light-emitting element in the light-emitting element array is damaged and recording the position of the damaged light-emitting element on the light-emitting element array; and, when it is detected that no damaged light-emitting element is present in the light-emitting element array, configuring the resolution of the display device to be a maximum resolution; and when it is detected that a damaged light-emitting element is present in the light-emitting element array, configuring the resolution of the display device to be an adjusted resolution, wherein the adjusted resolution is less than the maximum resolution.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a display device. Background Art

[0002] The manufacturing process of a micro light emitting diode (MicroLED) display device includes fabricating a light emitting element array composed of a plurality of MicroLEDs. Due to imperfections in the manufacturing process, defective MicroLEDs may exist in the light emitting element array.

[0003] After transferring millions of MicroLEDs to designated backplane locations for positioning and bonding (LED die to digital wafer, also known as mass transfer), how to repair defective MicroLED particles is an urgent problem to be solved. In order to enable the light-emitting element array with damaged MicroLEDs to display normally, currently, methods such as ultraviolet light irradiation repair technology, laser melting repair technology, or selective laser repair technology are commonly used to repair damaged MicroLED particles in the light-emitting element array; or a backup circuit design is used to design an additional backup MicroLED for each MicroLED particle in the MicroLED array. However, the size of MicroLED particles is very small, and the gaps between MicroLED particles are also very small, often reaching the micron level. Therefore, it is difficult and complicated to repair the damaged locations of MicroLED particles; and the cost of backup circuit design is also high. Summary of the Invention

[0004] In view of this, it is necessary to provide a method for manufacturing a display device, which can enable normal display when there are damaged light-emitting elements in the light-emitting element array of the display device without repairing the damaged light-emitting elements and activating spare light-emitting elements.

[0005] A method for manufacturing a display device, comprising:

[0006] A light-emitting element array including a plurality of light-emitting elements is formed on a substrate having a plurality of sub-pixels defined thereon, wherein each sub-pixel includes one of the light-emitting elements, and every four sub-pixels constitute a large sub-pixel. The four sub-pixels of each large sub-pixel are located in two adjacent rows and two adjacent columns, and the four light-emitting elements of the same large sub-pixel are configured to emit the same color.

[0007] Detecting whether each light emitting element in the light emitting element array is damaged and recording the position of the damaged light emitting element on the light emitting element array; and,

[0008] When it is detected that there are no damaged light-emitting elements in the light-emitting element array, the resolution of the display device is configured to be the maximum resolution; when it is detected that there are damaged light-emitting elements in the light-emitting element array, the resolution of the display device is configured to be an adjusted resolution, and the adjusted resolution is smaller than the maximum resolution.

[0009] Compared to the prior art, when a light-emitting element array in a display device contains a damaged light-emitting element, normal display can be achieved without repairing the damaged light-emitting element or activating a spare light-emitting element. When a damaged light-emitting element is present in the light-emitting element array, the resolution of the display device containing the light-emitting element array is configured to be an adjusted resolution. Although the resolution of the display device is lower than the maximum resolution, the display device containing the damaged light-emitting element can be sold at a reduced resolution, thereby improving the overall manufacturing yield. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 Flowchart of a method for manufacturing a display device according to a first embodiment of the present invention.

[0011] Figure 2 FIG. 1 is a schematic diagram of a light emitting element array composed of light emitting elements according to the first embodiment of the present invention.

[0012] Figure 3 This is a schematic diagram of a light emitting element array in which all large sub-pixels and all sub-pixels are arranged in a Bayer format according to the first embodiment of the present invention.

[0013] Figure 4 This is a schematic diagram of the display when all large sub-pixels emit the same light-emitting color and there is no damaged light-emitting element in the light-emitting element array according to the first embodiment of the present invention.

[0014] Figure 5 When the light emitting element array is Figure 4 Schematic diagram of the display when the light emitting elements are arranged in a certain form and there is no damaged light emitting element array.

[0015] Figure 6 This is a schematic diagram of the display when all large sub-pixels emit the same light-emitting color and there is a damaged light-emitting element in the light-emitting element array according to the first embodiment of the present invention.

[0016] Figure 7 When the light emitting element array is Figure 4 Schematic diagram of the display when the light emitting element array is arranged in a certain form and there is a damaged light emitting element in the light emitting element array.

[0017] Description of main component symbols

[0018] Light-emitting element 10

[0019] Light emitting element array 11

[0020] Sub-pixels 12, 12G, 12B, 12R

[0021] Large sub-pixels 13, 13G, 13B, 13R

[0022] The first diagonal I1

[0023] The second diagonal I2

[0024] The third diagonal I3

[0025] Unit 1 C1

[0026] Unit 2 C2

[0027] Large unit C3

[0028] Pixel unit 14

[0029] Display device 100

[0030] Substrate 101

[0031] Steps S1, S2, S3, S4

[0032] The following specific embodiments will further illustrate the present invention in conjunction with the above-mentioned drawings. DETAILED DESCRIPTION

[0033] The accompanying drawings illustrate embodiments of the present invention. The present invention may be implemented in a variety of different forms and should not be construed as being limited to the embodiments described herein. Rather, these embodiments are provided to make the present invention more comprehensive and complete and to enable those skilled in the art to more fully understand the scope of the present invention.

[0034] Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention pertains. It should also be understood that terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant art and should not be interpreted in an overly idealized or overly formal sense unless explicitly defined herein.

[0035] The "Bayer format" described herein refers to a format for arranging subpixels in digital images, also known as a Bayer array, invented by Eastman Kodak scientist Bryce Bayer. The human eye is more sensitive to green, so in the Bayer format, a subpixel emitting green (G) is the sum of a subpixel emitting red (R) and a subpixel emitting blue (B). Furthermore, in the Bayer array, the subpixels are composed of green subpixels, red subpixels, and blue subpixels. In the Bayer array, the four subpixels in two adjacent rows and two adjacent columns are two green subpixels, one red subpixel, and one blue subpixel. These four subpixels form a multi-row, multi-column matrix, thus forming the Bayer array.

[0036] The "resolution" mentioned herein refers to the number of pixels that a display device can display. When the display screen size of the display device is fixed, the higher the display resolution, the clearer the image.

[0037] See Figure 1 , the manufacturing method of the display device provided by the embodiment of the present invention comprises the following steps:

[0038] Step S1: forming a light-emitting element array including a plurality of light-emitting elements on a substrate having a plurality of sub-pixels defined thereon, wherein each sub-pixel includes one of the light-emitting elements, and every four sub-pixels constitute a large sub-pixel, and the four sub-pixels of each large sub-pixel are located in two adjacent rows and two adjacent columns, and the four light-emitting elements of the same large sub-pixel are set to emit the same color;

[0039] Step S2: Detecting whether each light emitting element in the light emitting element array is damaged and recording the position of the damaged light emitting element on the light emitting element array;

[0040] When it is detected that there is no damaged light emitting element in the light emitting element array, step S3 is performed: configuring the resolution of the display device including the light emitting element array to be the maximum resolution;

[0041] When a damaged light emitting element is detected in the light emitting element array, step S4 is executed: configuring the resolution of the display device including the light emitting element array to be an adjusted resolution, where the adjusted resolution is smaller than the maximum resolution.

[0042] The above-mentioned method for manufacturing a display device is applicable to the manufacture of an active light-emitting display device, such as a MicroLED display device and an Organic Light-Emitting Diode (OLED) display device. The light-emitting element may be a Micro LED or an OLED.

[0043] Please refer to Figure 2 In this embodiment, the plurality of light-emitting elements 10 are configured to emit light to display an image, i.e., to emit image light according to an image data signal. Assuming that all light-emitting elements 10 are capable of displaying an image, the display device has a maximum resolution (i.e., the maximum number of pixels that the display device can display).

[0044] In step S1, a driving circuit (not shown) for driving the light-emitting element 10 to emit light may be formed on the substrate 101, and a plurality of sub-pixels 12 are defined, and each sub-pixel 12 contains a light-emitting element 10. Every four sub-pixels 12 constitute a large sub-pixel 13, and the substrate 101 includes a plurality of non-overlapping large sub-pixels 13, and the four sub-pixels 12 of each large sub-pixel 13 are located in two adjacent rows and two adjacent columns. The four light-emitting elements 10 of the same large sub-pixel 13 are set to have the same luminous color, and the four light-emitting elements 10 located in the same large sub-pixel 13 emit the same color of light among the three primary colors of red, green and blue (RGB), that is, each large sub-pixel 13 emits light of a single color. Figure 2 As shown, a small square represents a sub-pixel 12, and a large sub-pixel 13 is shown. Figure 2 As shown in the dotted box in Figure 2 In the illustrated embodiment, each sub-pixel 12 has approximately equal area, and the four sub-pixels 12 in each large sub-pixel 13 are arranged in a rectangular shape. In one embodiment, the plurality of light-emitting elements 10 are MicroLEDs. The step of forming the light-emitting element array 11 on the substrate 101 includes transferring the plurality of light-emitting elements 10 to designated locations on the substrate 101 for positioning and bonding, such that each light-emitting element 10 is electrically connected to the driving circuit and can be individually driven to emit light.

[0045] In this embodiment, the light-emitting elements 10 in all large sub-pixels 13 emit the same color. That is, each light-emitting element 10 in the light-emitting element array 11 emits the same color, meaning that the light-emitting element array 11 emits monochromatic light. In this embodiment, all light-emitting elements 10 emit the same color of the three primary colors of red, green, and blue (RGB), meaning that the display device 100 can be a monochrome display device.

[0046] Reference Figure 3In this embodiment, the light-emitting elements 10 of the light-emitting element array 11 can emit light of different colors, that is, the display device 100 can be a multi-color display device (full-color array display device). In one embodiment, each light-emitting element 10 emits light of one of the three primary colors of red, green, and blue (RGB), and all large sub-pixels 13 and all sub-pixels 12 are arranged in the Bayer array format. The Bayer array format is a type of full-color array. Specifically, in the Bayer array format formed by all the sub-pixels 12, a first small unit C1 is formed by two green light-emitting sub-pixels 12G, one red light-emitting sub-pixel 12R, and one blue light-emitting sub-pixel 12B located in two adjacent rows and two adjacent columns and distributed along a first diagonal line I1; a second small unit C2 is formed by two green light-emitting sub-pixels 12G, one red light-emitting sub-pixel 12R, and one blue light-emitting sub-pixel 12B located in two adjacent rows and two adjacent columns and distributed along a second diagonal line I2, and the first diagonal line I1 and the second diagonal line I2 are perpendicular to each other. The first small cells C1 and the second small cells C2 are cyclically and alternately arranged in the X and Y directions to form the Bayer array format composed of all sub-pixels 12. In the Bayer array format composed of all large sub-pixels 13, a large cell C3 is formed by two large sub-pixels 13G emitting green light, one large sub-pixel 13R emitting red light, and one large sub-pixel 13B emitting blue light, located in two adjacent rows and two adjacent columns and arranged along a third diagonal line I3. The large cells C3 are repeatedly arranged in the X and Y directions to form the Bayer array format composed of all large sub-pixels 13. In this embodiment, the third diagonal line I3 is parallel to the first diagonal line I1. The order in which the first small cells C1 and the second small cells C2 are cyclically and alternately arranged in the X and Y directions is mutually influenced by the diagonal arrangement of the large sub-pixels 13G emitting green light. It can be understood that when the large sub-pixels 13G emitting green light are distributed along the third diagonal line I3 parallel to the first diagonal line I1, the order in which the first small units C1 and the second small units C2 are alternately distributed in the X direction and the Y direction is also determined to ensure that all large sub-pixels 13 and all small sub-pixels 12 of the light-emitting element array 11 simultaneously form the Bayer format arrangement. In other embodiments, the third diagonal line I3 of the two large sub-pixels 13G emitting green light may be parallel to the second diagonal line I2. In this case, the situation of the large sub-pixels 13G emitting green light distributed along the third diagonal line I3 is the same as that of the first small units C1 and the second small units C2. Figure 3 It can be understood that the cyclic alternation order of the first small unit C1 and the second small unit C2 when distributed in the X direction and the Y direction is exactly the same as Figure 3 On the contrary. The X direction and the Y direction are as follows Figure 3As shown, the X direction intersects with the Y direction and is perpendicular to each other. The cyclic alternation means that the first small unit C1 is spaced apart by the second small unit C2 in the X direction and in the Y direction, and the second small unit C2 is spaced apart by the first small unit C1 in the X direction and in the Y direction. In other embodiments, in a Bayer array format formed by all sub-pixels 12, a first small unit C1 is formed by two green-emitting sub-pixels 12G, one red-emitting sub-pixel 12R, and one blue-emitting sub-pixel 12B located in two adjacent rows and two adjacent columns, and in the first small unit C1, the green-emitting sub-pixel 12G is located in the same row, and the red-emitting sub-pixel 12R and the blue-emitting sub-pixel 12B are located in the same row; in a Bayer array format formed by all large sub-pixels 13, a large unit C3 is formed by two green-emitting large sub-pixels 13G, one red-emitting large sub-pixel 13R, and one blue-emitting large sub-pixel 13B located in two adjacent rows and two adjacent columns, and in the large unit C3, the green-emitting large sub-pixel 13G is located in the same row, and the red-emitting large sub-pixel 13R and the blue-emitting large sub-pixel 13B are located in the same row.

[0047] In a modified embodiment, all large sub-pixels 13 and all sub-pixels 12 are configured as a full-color array, that is, the light-emitting element array 11 includes sub-pixels 12 emitting three RGB colors, or sub-pixels emitting three or more different colors. Specifically, in the full-color array formed by all sub-pixels 12, a first small unit C1 is formed by two red-emitting sub-pixels 12R, one green-emitting sub-pixel 12G, and one blue-emitting sub-pixel 12B, located in two adjacent rows and two adjacent columns, and arranged along a first diagonal line I1. A second small unit C2 is formed by two red-emitting sub-pixels 12R, one green-emitting sub-pixel 12G, and one blue-emitting sub-pixel 12B, located in two adjacent rows and two adjacent columns, and arranged along a second diagonal line I2. In the full-color array formed by all large sub-pixels 13, a large unit C3 can be formed by two large sub-pixels 13R emitting red light and distributed along the third diagonal line I3 and located in two adjacent rows and two adjacent columns, one large sub-pixel 13G emitting green light, and one large sub-pixel 13B emitting blue light.

[0048] In another alternative embodiment, all large sub-pixels 13 and all sub-pixels 12 are configured as a full-color array, that is, the light-emitting element array 11 includes sub-pixels 12 emitting three RGB colors or sub-pixels 12 emitting three or more different colors. Specifically, the full-color array formed by all sub-pixels 12 comprises a first small unit C1 consisting of two blue-emitting sub-pixels 12B, one red-emitting sub-pixel 12R, and one green-emitting sub-pixel 12G, located in two adjacent rows and two adjacent columns and arranged along a first diagonal line I1. A second small unit C2 consists of two blue-emitting sub-pixels 12B, one red-emitting sub-pixel 12R, and one green-emitting sub-pixel 12G, located in two adjacent rows and two adjacent columns and arranged along a second diagonal line I2. In the full-color array formed by all large sub-pixels 13, a large unit C3 can be formed by two large sub-pixels 13B emitting blue light and distributed along the third diagonal line I3 in two adjacent rows and two adjacent columns, one large sub-pixel 13R emitting red light, and one large sub-pixel 13G emitting green light.

[0049] In another alternative embodiment, all large sub-pixels 13 and all sub-pixels 12 are arranged in a full-color array, that is, the light-emitting element array 11 includes sub-pixels 12 emitting three RGB colors or sub-pixels 12 emitting three or more different colors. The light-emitting element 10 can also emit any one of red, green, blue, and white. The first small unit C1 and the second small unit C2 can each be composed of a blue-emitting sub-pixel 12B, a red-emitting sub-pixel 12R, a green-emitting sub-pixel 12G, and a white-emitting sub-pixel (not shown) located in two adjacent rows and two adjacent columns. The large unit C3 can be composed of a blue-emitting large sub-pixel 13B, a red-emitting large sub-pixel 13R, a green-emitting large sub-pixel 13G, and a white-emitting large sub-pixel (not shown) located in two adjacent rows and two adjacent columns. In other alternative embodiments, the sub-pixels 12 comprising the first small unit C1 and the second small unit C2 can also emit yellow or other colors.

[0050] In step S2, the position of the light emitting element 10 in the light emitting element array 11 is specifically the position in the X direction and the Y direction of the light emitting element array 11. The X direction and the Y direction are as follows: Figure 2 and Figure 3As shown, the X-direction intersects and is perpendicular to the Y-direction. In this embodiment, in step S2, a circuit detection method is used to detect whether there are any damaged light-emitting elements 10 in the light-emitting element array 11. Specifically, each light-emitting element 10 is driven by a circuit to emit light, and then each light-emitting element 10 is detected to be emitting light and to determine whether the light-emitting brightness is normal. If the light-emitting element 10 is not emitting light, it is determined to be a damaged light-emitting element; or if the light-emitting brightness of the light-emitting element 10 is lower than a predetermined brightness, it is determined to be a damaged light-emitting element.

[0051] In step S3, when it is detected that there is no damaged light-emitting element 10 in the light-emitting element array 11 and the light-emitting colors of the light-emitting elements 10 of all large sub-pixels 13 are the same (that is, when the display device 100 is in monochrome display), it is set that each light-emitting element 10 of the light-emitting element array 11 participates in displaying an image and a sub-pixel 12 is a pixel unit 14 when the light-emitting element array 11 performs light-emitting display, as shown in FIG. Figure 4 That is, the display device 100 is configured to have a maximum resolution. A pixel unit 14 is an image pixel point when displaying an image, that is, the smallest display unit when displaying an image.

[0052] In step S3, when all large sub-pixels 13 and all sub-pixels 12 are set to a full-color array and it is detected that there are no damaged light-emitting elements 10 in the light-emitting element array 11, four sub-pixels 12 distributed in two adjacent rows and two columns are used as a pixel unit 14 when the display device 100 performs light-emitting display.

[0053] In one embodiment, when it is detected that there are no damaged light-emitting elements 10 in the light-emitting element array 11 and all large sub-pixels 13 and all sub-pixels 12 of the light-emitting element array 11 are set to a Bayer array format, each light-emitting element 10 of the light-emitting element array 11 is set to participate in displaying an image, and four sub-pixels 12 located in two adjacent rows and two adjacent columns are set as a pixel unit 14 for the display device 100 to perform light-emitting display. The pixel unit 14 includes two sub-pixels 12G emitting green light, one sub-pixel 12B emitting blue light, and one sub-pixel 12R emitting red light; Figure 5 In this embodiment, the first small cell C1 or the second small cell C2 forms a pixel unit 14 of the display device 100 for light-emitting display. That is, the display device 100 performs full-color display in a Bayer array format composed of the first small cell C1 and the second small cell C2. In this embodiment, in this pixel unit 14, the two green light-emitting sub-pixels 12G are arranged diagonally or non-diagonally.

[0054] In other embodiments, when all large sub-pixels 13 and all sub-pixels 12 are configured as a full-color array other than a Bayer array and it is detected that no damaged light-emitting elements 10 are present in the light-emitting element array 11, four sub-pixels 12 distributed across two adjacent rows and two columns form a pixel unit 14 when the display device performs light-emitting display. In these embodiments, the pixel unit 14 is formed by two red-emitting sub-pixels 12R, one green-emitting sub-pixel 12G, and one blue-emitting sub-pixel 12B; or by two blue-emitting sub-pixels 12B, one green-emitting sub-pixel 12G, and one red-emitting sub-pixel 12R; or by four sub-pixels 12 emitting different colors.

[0055] In step S4, when it is detected that there is a damaged light-emitting element 10 in the light-emitting element array 11, the step of configuring the resolution of the display device 100 to be the adjusted resolution includes: counting the number of damaged light-emitting elements in each large sub-pixel 13, recording the maximum number of damaged light-emitting elements 10 in all large sub-pixels 13 as M, and the adjusted resolution is 1 / 4 of the maximum resolution, and M is greater than 0 and less than 4. Because the number of sub-pixels 12 in each large sub-pixel 13 is 4, in order for each large sub-pixel 13 to display normally, the maximum number of damaged pixels that each large sub-pixel 13 can tolerate is 3, so M is less than 4. In this embodiment, when it is detected that there is a damaged light-emitting element 10 in the light-emitting element array 11 and the luminous colors of the light-emitting elements of all large sub-pixels are set to the same (that is, when the display device 100 is monochrome display), a large sub-pixel 13 is set as a pixel unit 14 when the display device performs luminous display, such as Figure 6 In this embodiment, when a damaged light-emitting element 10 is detected in the light-emitting element array 11 and all large sub-pixels 13 and all sub-pixels 12 are configured as a full-color array, four large sub-pixels 13 distributed in two adjacent rows and two columns are used as a pixel unit 14 when the display device 100 performs light-emitting display.

[0056] In this embodiment, when a damaged light-emitting element 10 is detected in the light-emitting element array 11, each large sub-pixel 13 uses N intact light-emitting elements of the four light-emitting elements that make up the large sub-pixel 13 for display, where N = 4 - M. That is, when a damaged light-emitting element is present in the light-emitting element array 11, all large sub-pixels 13 use the same number of light-emitting elements 10 for display. Thus, all pixel units 14 use the same number of light-emitting elements 10 for display, thereby ensuring uniform light emission across the light-emitting element array 11 during display.

[0057] In one embodiment, when a damaged light-emitting element 10 is detected in the light-emitting element array 11 and all large sub-pixels 13 and all sub-pixels 12 are configured as a Bayer array format, four large sub-pixels 13 distributed in two adjacent rows and two columns are configured as a pixel unit 14 of the display device 100 when performing light-emitting display, such as Figure 7 In this embodiment, the pixel unit 14 is formed by two large sub-pixels 13G emitting green light, one large sub-pixel 13R emitting red light, and one large sub-pixel 13B emitting blue light. The display device 100 performs full-color display using the Bayer array format formed by the pixel units 14, that is, the display device 100 performs full-color display using the Bayer array format formed by the large cells C3. In the pixel unit 14, the two large sub-pixels 13G emitting green light are arranged diagonally or non-diagonally. In other embodiments, when a damaged light-emitting element 10 is detected in the light-emitting element array 11 and all the large sub-pixels 13 and all the sub-pixels 12 are set to a full-color array that is not a Bayer array, a pixel unit 14 of the display device 100 can be formed by two large sub-pixels 13R that emit red light, one large sub-pixel 13G that emits green light, and one large sub-pixel 13B that emits blue light; or by two large sub-pixels 13B that emit blue light, one large sub-pixel 13G that emits green light, and one large sub-pixel 13R that emits red light; or by four large sub-pixels 13 that emit light of different colors.

[0058] In summary, the method for manufacturing a display device in an embodiment of the present invention performs light-emitting display in the form of maximum resolution and adjusted resolution, thereby being able to provide products with different resolutions. When there is a damaged light-emitting element 10 in the light-emitting element array 11, the resolution of the display device 100 including the light-emitting element array 11 is configured to be the adjusted resolution. Although the resolution of the display device 100 is less than the maximum resolution at this time, the display device 100 including the damaged light-emitting element 10 can be sold in a reduced specification form, thereby improving the overall manufacturing yield. Moreover, compared to the prior art, when there is a damaged light-emitting element 10 in the light-emitting element array 11 in the display device 100, the light-emitting element array 11 can also perform normal display without repairing the damaged light-emitting element 10 and activating a spare light-emitting element. Thus, the method for manufacturing a display device of the present invention reduces the time consumption of the light-emitting element 10 repair process and saves the cost of using a spare light-emitting element.

[0059] It is obvious to those skilled in the art that the present invention is not limited to the details of the above exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or essential features of the present invention. Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that the technical solutions of the present invention can be modified or replaced by equivalents without departing from the scope of the technical solutions of the present invention.

Claims

1. A method for manufacturing a display device, characterized in that: include: A light-emitting element array including a plurality of light-emitting elements is formed on a substrate having a plurality of sub-pixels defined thereon, wherein each sub-pixel includes one of the light-emitting elements, and every four sub-pixels constitute a large sub-pixel. The four sub-pixels of each large sub-pixel are located in two adjacent rows and two adjacent columns, and the four light-emitting elements of the same large sub-pixel are configured to emit the same color. detecting whether each light emitting element in the light emitting element array is damaged and recording the position of the damaged light emitting element on the light emitting element array; as well as When it is detected that no damaged light emitting element exists in the light emitting element array, configuring the resolution of the display device to be a maximum resolution; When a damaged light emitting element is detected in the light emitting element array, the resolution of the display device is configured to be an adjusted resolution, where the adjusted resolution is smaller than the maximum resolution.

2. The method for manufacturing a display device according to claim 1, wherein: When it is detected that there are no damaged light-emitting elements in the light-emitting element array and the light-emitting colors of the light-emitting elements of all large sub-pixels are set to be the same, each light-emitting element of the light-emitting element array is set to participate in displaying the image and one sub-pixel is used as a pixel unit when the display device performs light-emitting display.

3. The method for manufacturing a display device according to claim 1, wherein: When it is detected that there are no damaged light-emitting elements in the light-emitting element array and all large sub-pixels and all sub-pixels of the light-emitting element array are set to a full-color array, each light-emitting element of the light-emitting element array is set to participate in displaying an image, and four sub-pixels located in two adjacent rows and two adjacent columns are set as a pixel unit of the display device for light-emitting display.

4. The method for manufacturing a display device according to claim 3, wherein: The pixel unit is formed by two sub-pixels emitting green light, one sub-pixel emitting blue light and one sub-pixel emitting red light; or by two sub-pixels emitting red light, one sub-pixel emitting green light and one sub-pixel emitting blue light; or by two sub-pixels emitting blue light, one sub-pixel emitting green light and one sub-pixel emitting red light; or by four sub-pixels emitting different colors.

5. The method for manufacturing a display device according to claim 1, wherein: When it is detected that there are damaged light-emitting elements in the light-emitting element array, the step of configuring the resolution of the display device to be the adjusted resolution includes: counting the number of damaged light-emitting elements in each of the large sub-pixels, recording the maximum number of damaged light-emitting elements in all large sub-pixels as M, and the adjusted resolution is 1 / 4 of the maximum resolution, and M is greater than 0 and less than 4.

6. The method for manufacturing a display device according to claim 5, wherein: Each large sub-pixel uses N undamaged light-emitting elements among the four light-emitting elements constituting the large sub-pixel to emit light for display, where N=4-M.

7. The method for manufacturing a display device according to claim 5, wherein: When it is detected that there is a damaged light-emitting element in the light-emitting element array and the light-emitting colors of the light-emitting elements of all large sub-pixels in the light-emitting element array are set to be the same, a large sub-pixel is set as a pixel unit when the display device performs light-emitting display.

8. The method for manufacturing a display device according to claim 5, wherein: When all large sub-pixels and all sub-pixels are set to a full-color array and a damaged light-emitting element is detected in the light-emitting element array, four large sub-pixels distributed in two adjacent rows and two columns are used as a pixel unit when the display device performs light-emitting display.

9. The method for manufacturing a display device according to claim 8, wherein: The pixel unit is formed by two large sub-pixels emitting green light, one large sub-pixel emitting blue light and one large sub-pixel emitting red light; or by two sub-pixels emitting red light, one sub-pixel emitting green light and one sub-pixel emitting blue light; or by two sub-pixels emitting blue light, one sub-pixel emitting green light and one sub-pixel emitting red light; or by four large sub-pixels emitting different colors.

10. The method for manufacturing a display device according to claim 3 or 8, wherein: A first small unit is formed by two green-emitting sub-pixels, one red-emitting sub-pixel, and one blue-emitting sub-pixel arranged in a first diagonal line in two adjacent rows and columns. A second small unit is formed by two green-emitting sub-pixels, one red-emitting sub-pixel, and one blue-emitting sub-pixel arranged in a second diagonal line in two adjacent rows and columns. The first diagonal line intersects the second diagonal line, and the first small unit and the second small unit are alternately arranged in the X and Y directions. A large unit is formed by two green-emitting large sub-pixels, one red-emitting large sub-pixel, and one blue-emitting large sub-pixel arranged in a third diagonal line in two adjacent rows and columns. The third diagonal line is parallel to the first diagonal line. The large units are repeatedly arranged in the X and Y directions. Thus, all sub-pixels and all large sub-pixels simultaneously form a Bayer array format.

Images