Display Panel Dummy Region Layout for In-Process Defect Inspection

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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

VSEngineering Contradiction Analysis

1Reliability

If inspection is performed only on finished products, then manufacturing process is simpler, but defect identification capability is reduced

Engineering Contradiction:
Improvedefect identification capabilityVSAvoidinspection process complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

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.

Inventive Principle:
Principle #10Preliminary action

2Reliability

If TEG structure is added to enable real-time inspection, then defect detection capability is improved, but device structure becomes more complex

Engineering Contradiction:
Improvereal-time inspection capabilityVSAvoidstructure complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

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.

Inventive Principle:
Principle #26Copying

3Manufacturing precision

If inspection points are increased during manufacturing, then quality control is improved, but manufacturing time is extended

Engineering Contradiction:
Improvequality control levelVSAvoidmanufacturing cycle time
Core Design Contradiction:
Manufacturing precisionVSLoss of time

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.

Inventive Principle:
Principle #20Continuity of useful action

Data Source

PatentUS20260013296A1Display panel
Publication Date: 2026.01.08 LG DISPLAY CO LTD
  • US20260013296A1 patent drawing
  • US20260013296A1 patent drawing
  • US20260013296A1 patent drawing

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.