Display Repair Pattern Layout to Stop Laser-Induced Active Layer Cracks
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Solution Overview
Problem
Existing display devices face challenges in repairing malfunctioning pixels without damaging the insulating layer and light emitting element, and in preventing damage to lower polarizers when using laser beam cutting.
Innovation Solution
A display device structure is developed where a repair pattern is stacked under an active layer, allowing for the cutting of the active layer using a laser beam to isolate malfunctioning pixels from the light emitting element, thereby preventing damage to the insulating layer and lower polarizers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a repair pattern is stacked under an active layer and cut by a laser beam, then malfunctioning pixels can be repaired by cutting the active layer, but cracks may propagate to the active layer causing it to be cut
Solution Approach 1:
A buffer layer is introduced as an intermediary between the repair pattern and the active layer. This buffer layer absorbs and dissipates the mechanical stress and cracks generated during laser cutting of the repair pattern, preventing crack propagation to the active layer while still allowing the repair process to proceed effectively
2Ease of repair
If laser beam cutting is used to repair pixels, then the active layer can be cut to isolate malfunctioning pixels, but the insulating layer and light emitting element may be damaged
Solution Approach 1:
The patent segments the pixel structure into distinct layers with the repair pattern positioned in a specific location underneath the active layer. By cutting only the repair pattern and active layer at the pixel level, the isolation is achieved without affecting the insulating layer and light emitting element located in other spatial zones
3Ease of repair
If laser beam cutting is used to cut the conductive layer for pixel repair, then malfunctioning pixels can be isolated, but the lower polarizer may be damaged
Solution Approach 1:
The patent transitions from cutting the conductive layer in the horizontal plane to cutting the repair pattern in the vertical dimension underneath the active layer. This dimensional change allows laser beam cutting to isolate malfunctioning pixels by cutting the active layer above the repair pattern, avoiding exposure of the lower polarizer to the laser beam and preventing its damage
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
This solution effectively repairs malfunctioning pixels by cutting the active layer, preventing damage to the light emitting element and lower polarizers, and ensuring reliable pixel repair without compromising the display device's integrity.
Implementation Method 1
when the repair pattern is cut by a laser beam emitted from the outside
Implementation Method 2
The repair pattern may be an electrode in an isolated form, the electrode being formed of a metal material
Data Source
AI summary
A display device includes: a substrate on which circuit elements constituting a pixel are arranged; a repair pattern arranged overlying the substrate; a buffer layer covering the repair pattern; an active layer arranged overlying the buffer layer; a conductive layer which is arranged overlying the active layer and on which electrodes of the circuit elements are arranged; an overcoat layer covering the conductive layer, and a light emitting element arranged overlying the overcoat layer. The repair pattern is arranged in such a manner that one region thereof overlaps the active layer.