Laser Removing Pixel Electrode for LCD Repair
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Solution Overview
Problem
Conventional methods for repairing pixel structures in LCDs, such as laser welding and laser cutting, are complex and not cost-effective, requiring numerous operations to transform defective pixels into dark spots.
Innovation Solution
A method involving a laser removing process to electrically insulate the pixel electrode from the active device by removing it from the contact opening, simplifying the repair process and transforming defective pixels into dark spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional laser welding and laser cutting methods are used to repair pixel structures, then defective pixels can be transformed into dark spots, but the repair process becomes complex and requires numerous operations
Solution Approach 1:
The patent extracts and removes only the necessary portion of the pixel electrode material from the contact opening using a targeted laser removing process. By selectively removing just the excess pixel electrode material that causes the electrical connection issue, the method achieves pixel repair without requiring complex multi-step welding and cutting operations, thus simplifying the overall repair process while maintaining effectiveness
Solution Approach 2:
The patent replaces conventional mechanical laser welding and cutting operations with a laser removing process. Instead of using mechanical contact methods or multiple thermal processing steps, the invention uses focused laser energy to precisely ablate and remove the problematic pixel electrode material, substituting a simpler thermal field-based approach for complex mechanical operations
2Reliability
If conventional laser welding and laser cutting methods are used to repair pixel structures, then defective pixels can be transformed into dark spots, but the repair process is not cost-effective
Solution Approach 1:
By extracting and removing only the specific defective portion of the pixel electrode through a targeted laser removing process, the method eliminates the need for expensive and time-consuming conventional welding and cutting operations. This selective removal approach reduces material waste, processing time, and operational costs, making the repair process more cost-effective while achieving the same reliability outcome
Solution Approach 2:
The patent applies the principle of discarding the defective pixel electrode material that causes the electrical connection problem. By removing and discarding only the problematic portion rather than attempting to repair or rework the entire pixel structure, the method achieves cost-effective repair by minimizing material waste and processing resources while maintaining the functional integrity of the remaining pixel components
3Ease of repair
If conventional laser welding and laser cutting methods are used, then pixel structures can be repaired, but plenty of cutting and welding operations are required
Solution Approach 1:
The patent extracts and removes only the necessary portion of the pixel electrode material in a single targeted laser removing operation. This approach eliminates the need for multiple sequential cutting and welding operations, reducing the total number of steps required for pixel repair while maintaining the effectiveness of transforming defective pixels into dark spots, thus improving productivity
Solution Approach 2:
The laser removing process is designed to perform the necessary material removal in advance, creating the appropriate electrical insulation condition before final pixel activation. By pre-removing the excess pixel electrode material that causes electrical connection issues, the method eliminates the need for subsequent corrective welding or cutting operations, reducing the overall number of steps required for successful pixel repair
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
The method effectively transforms defective pixels into dark spots with fewer and simpler operations compared to conventional methods, improving efficiency and cost-effectiveness.
Implementation Method 1
A laser removing process is performed to remove at least one portion of the pixel electrode in the contact opening
Data Source
AI summary
A method of repairing a pixel structure is provided. In the method, the pixel structure on a substrate is provided and includes a scan line, a data line, an active device, an insulating layer, and a pixel electrode. The scan line and the data line are located on the substrate. The active device is located on the substrate and electrically connected to the scan line and the data line. The insulating layer covers the scan line, the data line, and the active device and has a contact opening. The pixel electrode is located on the insulating layer and fills the contact opening to electrically connect the active device. A laser removing process is performed to remove the pixel electrode in the contact opening, such that the pixel electrode is electrically insulated from the active device.