Display Repair Pattern Layout for Crack-Based Pixel Isolation
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Solution Overview
Problem
Existing display device repair methods using laser beams often damage insulating layers and light emitting elements when cutting conductive layers, and can also harm lower polarizers due to specific wavelength usage.
Innovation Solution
A display device structure with a repair pattern stacked under the active layer, allowing the active layer to be cut using a laser beam, thereby isolating malfunctioning pixels from the light emitting element, and a method involving a substrate, repair pattern, buffer layer, active layer, conductive layer, and light emitting element, where the repair pattern is cut to propagate a crack to the active layer, separating it from the conductive layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the conductive layer is cut using a laser beam to repair a malfunctioning pixel, then the pixel can be isolated, but the insulating layer and light emitting element are damaged
Solution Approach 1:
The patent divides the active layer into multiple separate regions (first active layer region, second active layer region, third active layer region) that are electrically isolated from each other. This segmentation allows the malfunctioning pixel to be isolated by cutting only the active layer connections without affecting other layers, resolving the contradiction between repair capability and protection of other components.
Solution Approach 2:
The patent applies different structural configurations to different regions of the active layer. Specifically, the first active layer region has a different connection structure compared to the second and third regions, allowing localized repair actions to affect only specific pixels or regions without propagating damage to the entire device.
2Manufacturing precision
If a specific wavelength laser beam is used to cut the conductive layer, then cutting precision is improved, but the lower polarizer is damaged
Solution Approach 1:
Instead of cutting the conductive layer from the conventional approach that risks damaging the polarizer, the patent inverts the approach by cutting the active layer which is positioned above the conductive layer. This inversion allows precise laser cutting to be performed on the active layer without the laser beam reaching and damaging the lower polarizer, while still achieving the goal of isolating malfunctioning pixels.
3Ease of repair
If the repair pattern is cut by a laser beam, then the malfunctioning pixel is isolated, but a crack propagates to the active layer causing it to be cut
Solution Approach 1:
The patent designs the active layer with multiple separate regions and buffer layers positioned between the repair pattern and the active layer. These buffer layers act as cushioning elements that absorb and stop crack propagation when the repair pattern is cut by a laser beam, preventing cracks from reaching and damaging the active layer while still allowing successful pixel isolation.
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
Effectively repairs malfunctioning pixels by cutting the active layer instead of the conductive layer, preventing damage to insulating layers and light emitting elements, and avoiding damage to lower polarizers by using an infrared laser beam that does not affect the polarizer.
Implementation Method 1
when the repair pattern is cut by a laser beam emitted from the outside
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.