Display Module LED Repair Using Continuous Laser Transfer

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Solution Overview

Problem

Defective pixels in display modules due to missing or defective LEDs during manufacturing, leading to off-dots when power is applied, are not effectively addressed by existing technologies.

Innovation Solution

A laser transfer method is employed to repair display modules by detecting missing LED positions and transferring LEDs from a transfer substrate to the target substrate using a laser beam, moving the substrates in opposite directions to align and fill in missing LEDs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional manufacturing processes are used for display modules, then production speed can be maintained, but defective pixels occur due to missing or defective LEDs

Engineering Contradiction:

Improvedisplay qualityVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent prepares a transfer substrate with additional LEDs in advance before the display module assembly is complete. This preliminary preparation allows defective LEDs to be replaced without stopping production, as the replacement LEDs are already positioned and ready for transfer when defects are detected during assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent recovers functional LEDs from the transfer substrate to replace defective LEDs on the target substrate. Instead of discarding the transfer substrate after use, the system enables recovery and reuse of good LEDs, thereby maintaining production efficiency while improving display quality.

Inventive Principle:

Principle #34Discarding and recovering

2Reliability

If defective LEDs are replaced during manufacturing, then display quality improves, but additional time and complexity are required

Engineering Contradiction:

Improvedisplay qualityVSAvoidrepair process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces a transfer substrate as an intermediary component between the LED source and the target display substrate. This intermediary holds reserve LEDs and enables defect replacement without requiring complex reconfiguration of the manufacturing system, thus improving quality while limiting complexity increase.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent employs a laser transfer mechanism to replace mechanical handling methods for LED placement. The laser-based transfer system automatically transfers LEDs from the transfer substrate to the target substrate at precise locations, reducing manual intervention and simplifying the repair process complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If a laser transfer method is used to replace LEDs, then repair precision improves, but the process time increases

Engineering Contradiction:

ImproveLED placement precisionVSAvoidrepair time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent enables continuous operation by performing LED replacement during the normal assembly process rather than as a separate post-processing step. The laser transfer method operates continuously as the target substrate moves through the assembly line, maintaining precision while minimizing additional time through uninterrupted processing.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent uses a dynamic laser transfer system that can adjust its operation in real-time based on the position and status of LEDs. The laser transfer mechanism moves dynamically with the substrate and can selectively activate only when and where needed, achieving high precision without proportionally increasing overall process time.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Effectively repairs display modules by replacing missing LEDs, improving production efficiency and reducing manufacturing costs through precise laser transfer without the need for additional devices.

Implementation Method 1

transferring a laser consecutively to the LED missing positions by moving the target substrate and the transfer substrate at a constant speed by operating the first stage and the second stage in a row direction or a column direction

Methodology Applied

Scientific EffectLaser beam radiation: Laser

Implementation Method 2

LEDs may be transferred to the LED missing positions on the target substrate by radiating a laser beam from the laser onto the transfer substrate based on the LED missing positions of the target substrate reaching a laser beam irradiation position while the target substrate and the transfer substrate are in movement

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS12557456B2Display module and method for repairing display module

Publication Date: 2026.02.17 SAMSUNG ELECTRONICS CO LTD

AI summary

A method for repairing a display module and a display module repaired by the method are provided. The method for repairing a display module includes: detecting light-emitting diode (LED) missing positions on a target substrate; loading the target substrate onto a first stage; loading a transfer substrate onto a second stage; arranging the target substrate and the transfer substrate by operating the first stage and the second stage; and transferring a laser consecutively to the LED missing positions by moving the target substrate and the transfer substrate at a constant speed by operating the first stage and the second stage in a row direction or a column direction.