Display Panel Dummy Region Layout for In-Process Defect Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing technologies have not effectively addressed the need for real-time inspection and defect identification in the manufacturing process of display devices including inorganic light-emitting elements, such as micro LEDs, to ensure high-quality production and yield.
Innovation Solution
A display panel design incorporating a testing element structure (TEG) structure with a plurality of dummy light-emitting elements, a third electrode, and a metal portion to facilitate data extraction and inspection, which includes a display panel having enhanced yield, and a non-display region outside the display region, wherein each of the display region and the non-display region includes a first electrode and a light-emitting element disposed on the first electrode, and the non-display region further includes a dummy region including a third electrode disposed on the light-emitting element in the non-display region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inspection is performed only on finished products, then manufacturing process is simpler, but defect identification capability is reduced
Solution Approach 1:
The patent applies preliminary action by incorporating a testing element group (TEG) structure during the manufacturing process that enables inspection at multiple stages before final product completion. The TEG structure includes dummy light-emitting elements and electrodes that allow real-time monitoring of manufacturing quality, enabling defect identification early in the production process rather than only at the finished product stage.
2Reliability
If TEG structure is added to enable real-time inspection, then defect detection capability is improved, but device structure becomes more complex
Solution Approach 1:
The patent applies copying by creating a testing element group that replicates the functional characteristics of the actual light-emitting elements in a simplified form. The TEG structure includes dummy light-emitting elements and electrode configurations that mirror the electrical and optical properties of production elements, allowing inspection without requiring complex measurement equipment. This copying approach enables real-time inspection while keeping the additional structure relatively simple and manageable.
3Manufacturing precision
If inspection points are increased during manufacturing, then quality control is improved, but manufacturing time is extended
Solution Approach 1:
The patent applies continuity of useful action by designing the TEG structure to enable continuous or near-continuous inspection during the manufacturing process. The testing elements are integrated into the production line flow, allowing quality monitoring to occur simultaneously with manufacturing operations rather than requiring separate inspection stages. This integration maintains high manufacturing precision while minimizing interruptions and time losses.
Data Source
AI summary
A display panel includes a display region and a non-display region outside the display region. In one or more examples, each of the display region and the non-display region includes a first electrode and a light-emitting element disposed on the first electrode, the display region further includes a second electrode disposed on the light-emitting element in the display region, and the non-display region further includes a dummy region including a third electrode disposed on the light-emitting element in the non-display region. In one or more aspects, the display panel improves the yield of the final product.


