Display Panel Bonding Layout for Micro-LED Transfer Repair
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Solution Overview
Problem
The yield of mass transfer technology for Micro-LEDs is low, and there is a need to improve both the transfer and repair processes due to the tight arrangement of Micro-LEDs, making it difficult to meet display standards.
Innovation Solution
A display panel design with normal and redundant bonding areas on the driving backplane, where the normal bonding areas and redundant bonding areas form groups, allowing for increased distance between sub-pixels and enabling the introduction of patched sub-pixels with the same emitting color to replace defective ones, thereby improving repair yield and reducing interference during transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If Micro-LEDs are arranged tightly to increase display resolution, then display quality is improved, but the yield of mass transfer and repair processes deteriorates
Solution Approach 1:
The bonding areas are segmented into normal bonding areas and redundant bonding areas. The normal bonding areas are used for standard sub-pixel placement, while redundant bonding areas serve as backup locations for defective pixels. This segmentation allows the system to maintain high display resolution through tight arrangement while providing dedicated zones for repair operations, thus resolving the contradiction between display quality and repair yield.
Solution Approach 2:
Redundant bonding areas are prepared in advance during the manufacturing process, before any defects are detected. These pre-prepared bonding areas with matching electrical connections are ready to receive replacement sub-pixels immediately when defects are identified, eliminating the need for complex re-routing or additional manufacturing steps, thereby maintaining high yield despite tight arrangement constraints.
2Measurement precision
If the distance between adjacent normal bonding areas is reduced to increase sub-pixel density, then display resolution is improved, but interference between adjacent sub-pixels increases and transfer yield deteriorates
Solution Approach 1:
Redundant bonding areas act as intermediary elements between normal bonding areas. By positioning redundant bonding areas adjacent to normal bonding areas with appropriate spacing, they serve as buffer zones that reduce direct interference between adjacent sub-pixels in normal bonding areas, allowing tighter arrangement while maintaining signal integrity and reducing crosstalk.
3Productivity
If redundant bonding areas are added to enable repair operations, then repair yield is improved, but device complexity increases
Solution Approach 1:
Redundant bonding areas are designed with the same electrical connection structure as normal bonding areas, allowing them to serve multiple functions: they can remain inactive during normal operation and immediately activate to replace defective sub-pixels when needed. This universal design approach enables repair functionality without requiring complex additional structures, thus improving repair yield while minimizing increases in device complexity.
Data Source
AI summary
A display panel and a preparation method therefor are provided. The display panel includes: a driving backplate, a first surface of which is provided with normal bonding areas and redundant bonding areas, at least one of first distances between every two normal bonding areas, which are adjacent to each other is greater than at least one of second distances between each normal bonding area and a corresponding redundant bonding area which is adjacent to the normal bonding area, and at least one normal bonding area and at least one redundant bonding area adjacent thereto constitute a bonding group; and a light emitting layer, located on the first surface and including sub-pixels electrically connected to the normal bonding areas or the redundant bonding areas, and the normal bonding area and the redundant bonding area of the same bonding group are electrically connected to sub-pixels with the same emitting color.