Detection Substrate with Embedded Electrodes for Micro LED Testing
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Solution Overview
Problem
Current mass detection methods for Micro/Mini LEDs cannot guarantee that all LEDs will be functional before mass transfer, leading to high repair ratios and inefficiencies in production due to inability to detect non-functional LEDs with qualified appearances.
Innovation Solution
A detection substrate with embedded electrode columns, a driving circuit, and bonding pads on a base substrate, connected via a conductive adhesive layer, allows for electrical testing and lighting detection of massive LEDs before mass transfer, ensuring product yield and reducing repair ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current mass detection methods are used for Micro/Mini LEDs, then production can proceed, but non-functional LEDs with qualified appearances cannot be detected, leading to high repair ratios
Solution Approach 1:
The patent implements preliminary detection of LED functionality before mass transfer by fabricating electrode columns, conductive adhesive layers, and driving circuits on the detection substrate in advance. This allows electrical testing to be performed prior to the mass transfer process, identifying non-functional LEDs that would otherwise pass appearance inspection, thereby resolving the contradiction between maintaining manufacturing ease and improving detection capability.
Solution Approach 2:
The patent introduces a detection substrate as an intermediary component between the LED array and the final display assembly. This substrate includes electrode columns that make electrical contact with LEDs, conductive adhesive layers for connection, and driving circuits for controlling and detecting LED functionality. The intermediary enables comprehensive electrical testing without complicating the main manufacturing process.
2Measurement precision
If detection substrate with embedded electrode columns and driving circuit is implemented, then detection precision improves, but device complexity increases
Solution Approach 1:
The patent merges multiple functional components into a single integrated detection substrate: electrode columns for electrical contact, conductive adhesive layers for connection, and driving circuits for control and detection are all fabricated on the same substrate. This consolidation improves detection precision while managing complexity through integration rather than separate components.
Solution Approach 2:
The detection substrate serves multiple functions simultaneously: it provides mechanical support for the LED array, establishes electrical connections through electrode columns, enables electrical testing via driving circuits, and facilitates mass transfer. This multi-functionality achieves high detection precision without proportionally increasing device complexity.
3Productivity
If mass detection of LEDs is performed before mass transfer, then transfer efficiency improves, but production process complexity increases
Solution Approach 1:
The patent performs LED functionality detection as a preliminary step before mass transfer by incorporating driving circuits that can test each LED's electrical characteristics. Non-functional LEDs are identified and removed before the mass transfer process, ensuring only functional LEDs are transferred. This preliminary action improves transfer efficiency by preventing defective units from entering the transfer process.
Solution Approach 2:
The detection substrate includes integrated driving circuits that autonomously control and detect LED functionality without requiring external testing equipment during the detection phase. The substrate itself provides the means for testing, reducing the need for additional complex production equipment and simplifying the overall production process while maintaining high transfer efficiency.
Data Source
AI summary
A detection substrate, a preparation method thereof, a detection device and a detection method are provided. A detection substrate includes a base substrate, wherein the base substrate includes multiple through holes, and electrode columns are embedded in the multiple through holes; the base substrate comprises a detection region and a bonding pad region, the detection region includes a driving circuit, and the bonding pad region is provided with bonding pads; and the bonding pads are connected with the electrode columns through the driving circuit.