Display Panel LED Connection Pads for Repairable Reliability
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Solution Overview
Problem
Display panels with damaged, malfunctioned, or low-performance LEDs experience degraded display quality, necessitating a solution to improve and maintain display quality.
Innovation Solution
A display panel design and manufacturing method that includes an array substrate with specific connection pads and light-emitting diodes (LEDs) where damaged or low-efficiency LEDs are repaired by being completely overlapped and electrically connected to specific connection pads, ensuring proper functionality and display quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LEDs are densely arranged in display panels, then display quality and brightness are improved, but the probability of LED damage and malfunction increases
Solution Approach 1:
The patent divides the connection structure into multiple independent connection pads (first connection pad, second connection pad, third connection pad) that can independently connect to different LEDs. This segmentation allows individual LED replacement without affecting the entire display panel, resolving the contradiction by enabling high-density LED arrangement while maintaining reliability through modular connection design.
Solution Approach 2:
The patent implements local quality by creating different connection configurations for different regions. Specifically, the first connection pad is completely overlapped by a first LED, the second connection pad is completely overlapped by a second LED, and the third connection pad is partially overlapped. This allows different connection strategies in different locations, improving both display quality and reliability.
2Reliability
If damaged LEDs are replaced with new LEDs, then display quality is restored, but manufacturing complexity and time increase
Solution Approach 1:
The patent applies preliminary action by pre-designing multiple connection pads and establishing redundant connection paths before LED installation. The first, second, and third connection pads are prepared in advance with different overlap configurations, enabling quick replacement of damaged LEDs without complex manufacturing processes, thus restoring display quality while maintaining manufacturing efficiency.
Solution Approach 2:
The connection pads are designed with multi-functionality to serve multiple purposes. The same connection pad structure can connect to different LEDs (first LED, second LED, or third LED) depending on which LED is functional. This universal design simplifies the replacement process and maintains productivity while ensuring reliability.
3Reliability
If connection pads are completely overlapped by LEDs, then electrical connection is improved, but repairability and replacement flexibility decrease
Solution Approach 1:
The patent segments the connection system into multiple independent connection pads with different overlap characteristics. The first connection pad is completely overlapped for strong electrical connection, the second connection pad is completely overlapped for alternative connection, and the third connection pad is partially overlapped for easy access. This segmentation enables both reliable electrical connection and flexible repair options.
Solution Approach 2:
The patent inverts the traditional approach by not making all connection pads completely overlapped. Instead, it deliberately creates a partially overlapped third connection pad that provides both electrical connection and repair accessibility. This inversion resolves the contradiction by showing that complete overlap is not always necessary for reliable connection.
Data Source
AI summary
A display panel including an array substrate, a first sub-pixel, a second sub-pixel, and a first light-emitting diode is provided. The array substrate includes a first connection pad and a second connection pad. The first sub-pixel includes a first driving unit electrically connected to the first connection pad. The second sub-pixel includes a second driving unit electrically connected to the second connection pad. The first light-emitting diode completely overlaps and is physically isolated from the second connection pad. The first light-emitting diode is not completely overlapped and is electrically connected to the first connection pad. A manufacturing method of a display panel is also provided.