Light Emitting Device Defect Repair via Dummy Element
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Solution Overview
Problem
Conventional light-emitting devices with multiple elements mounted on a substrate often need to be scrapped when one element becomes defective, as replacing the defective element without disrupting the optical performance and maintaining emission points is challenging.
Innovation Solution
The solution involves mounting new light-emitting elements on the same wiring pattern as the defective ones, using a shared sealing member to cover the defective element or its trace, which allows for minimal disruption of the emission points and simplifies the manufacturing process, reducing waste and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a defective light-emitting element is replaced by mounting a new element on the same wiring pattern, then the device can be reused and manufacturing costs are reduced, but the optical performance may be disrupted and emission points may shift
Solution Approach 1:
A dummy light-emitting element is mounted on the wiring pattern in advance during the initial manufacturing process. This dummy element occupies the space and defines the emission point position beforehand, allowing the new light-emitting element to be replaced at the same location without shifting the emission point, thus maintaining optical performance while enabling device reuse
Solution Approach 2:
The dummy light-emitting element serves as an intermediary structure that preserves the original emission point position. It acts as a placeholder that maintains the optical path and emission characteristics, allowing replacement of defective elements without disrupting the overall optical performance of the device
2Manufacturing precision
If additional wiring patterns are created for replacement elements, then emission point position can be maintained, but device complexity and manufacturing costs increase
Solution Approach 1:
The same wiring pattern serves multiple functions: it originally connects the first light-emitting element, and after the dummy element is removed, it connects the new light-emitting element. This multi-functionality eliminates the need for additional dedicated wiring patterns for replacement elements, reducing device complexity while maintaining emission point position accuracy
Solution Approach 2:
The dummy light-emitting element is temporarily mounted during manufacturing to preserve emission point position, then removed after serving its purpose. This temporary structure enables the original wiring pattern to be reused for the new element, avoiding the need for permanent additional wiring and reducing overall device complexity
Data Source
AI summary
The light-emitting device has a plurality of light-emitting elements that is mounted on one or more wiring patterns on a substrate. A new light-emitting element that replaces a defective element is mounted on the same wiring pattern on which the defective element is mounted. The defective element or a trace that remains alter removal of the defective element is sealed by a same sealing member by which the new light-emitting element is sealed.