Laser Repair of Display Defective Pixel Interfaces
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Solution Overview
Problem
Existing display devices, such as LCDs, face issues with defective pixel areas that cannot be efficiently repaired, leading to errors in image display.
Innovation Solution
A method involving the use of laser beams to create protrusion-depression surfaces on the interfaces of defective pixel areas, followed by burning these surfaces and flowing black material to mask the defects, effectively converting the defective areas into dark spots to prevent image distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a defective pixel area is left unrepaired, then the display device structure remains simple, but image quality deteriorates due to errors in defective pixels
Solution Approach 1:
The patent replaces complex mechanical repair processes with laser-based methods. A laser beam is used to melt the black matrix material and form a protrusion-depression surface, eliminating the need for mechanical removal and replacement of defective pixel components. This substitution of mechanical operations with optical/thermal processes simplifies the overall repair procedure while maintaining image quality.
Solution Approach 2:
The patent changes the physical state and geometric parameters of the black matrix material through laser irradiation. The material transitions from solid to molten state, and the surface geometry changes to form protrusion-depression structures. These parameter changes enable the material to fill defective pixel areas and mask defects effectively, improving image quality without complex mechanical manipulation.
2Productivity
If conventional repair methods are used for defective pixels, then manufacturing precision can be maintained, but the repair time and productivity are reduced
Solution Approach 1:
The patent implements continuous laser irradiation to melt the black matrix material and form the protrusion-depression surface in a single uninterrupted process. This continuous action eliminates the need for multiple separate steps (removal, cleaning, filling, drying), significantly reducing repair time and improving productivity compared to conventional multi-step repair methods.
Solution Approach 2:
By replacing mechanical repair operations with laser-based thermal and optical processes, the patent achieves faster repair times. The laser method directly modifies the material state and surface geometry in seconds, whereas mechanical methods require multiple manual or automated steps that collectively take much longer, thus reducing loss of time and improving productivity.
3Reliability
If black material is flowed to mask defects, then the defective pixel areas are converted to dark spots, but additional materials and processing steps are required
Solution Approach 1:
The patent applies the self-service principle by using the black matrix material itself as the masking agent. The laser-melted black matrix automatically flows to the defective pixel areas and forms the protrusion-depression surfaces that mask the defects. This eliminates the need for external masking materials or complex multi-material processing, simplifying the repair process while maintaining effective defect masking.
Solution Approach 2:
The patent changes the physical parameters of the black matrix material through laser heating, transforming it from a solid structural component into a flowable material that can be used for masking. This parameter change enables the same material to serve dual purposes: maintaining the display structure and masking defective pixels, thereby simplifying the repair process without compromising masking effectiveness.
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 method allows for the efficient repair of defective pixel areas by converting them into dark spots, thereby maintaining image quality and extending the lifespan of display devices.
Implementation Method 1
irradiating a first laser beam to a first interface provided between a first layer and a second layer that contact each other corresponding to the defective pixel area to form a protrusion-depression surface
Implementation Method 2
irradiating a first laser beam to a first interface provided between a first layer and a second layer that contact each other corresponding to the defective pixel area to form a protrusion-depression surface
Implementation Method 3
irradiating a second laser beam to the protrusion-depression surfaces provided in one or more surfaces of the first and second layers to burn the protrusion-depression surface
Implementation Method 4
irradiating a second laser beam to the protrusion-depression surfaces provided in one or more surfaces of the first and second layers to burn the protrusion-depression surface
Implementation Method 5
flowing a black material melted from a black matrix that neighbors the first interface to the protrusion-depression surface
Implementation Method 6
flowing a black material melted from a black matrix that neighbors the first interface to the protrusion-depression surface
Data Source
AI summary
A method for repairing a display device including a defective pixel area where a failure has occurred includes irradiating a first laser beam to a first interface provided between a first layer and a second layer that contact each other corresponding to the defective pixel area to form a protrusion-depression surface in one or more surfaces of the first layer and the second layer that form the first interface; and irradiating a second laser beam to the protrusion-depression surfaces provided in one or more surfaces of the first and second layers to burn the protrusion-depression surface.