LED Display Pixel Layout With Black Sub-Pixels for Defect Repair
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Solution Overview
Problem
Display devices using LEDs face challenges with alignment and placement issues during substrate transfer, leading to defective sub-pixels, which increases manufacturing costs and complexity due to the need for redundant sub-pixels and inefficient repair processes.
Innovation Solution
A display device configuration with a substrate featuring a plurality of pixels, including light emitting diodes, color conversion members, and a light shielding pattern, where extra sub-pixels are formed to replace defective ones, reducing the number of LEDs required and simplifying the manufacturing and repair processes by using only one type of LED and eliminating the need for additional transferring steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple types of LEDs are used to create sub-pixels, then color display capability is improved, but transferring complexity and alignment difficulty increase
Solution Approach 1:
The patent applies universality by using a single type of blue LED that serves multiple functions: it directly provides blue sub-pixels and, through integration with color conversion members (quantum dots or phosphors), generates green and red sub-pixels. This multi-functional approach eliminates the need to transfer separate red, green, and blue LEDs, reducing transferring complexity while maintaining full color display capability.
Solution Approach 2:
The patent introduces color conversion members (quantum dots or phosphors) as intermediaries that convert blue light from a single LED type into other colors. This intermediary mechanism allows one LED type to effectively produce multiple colors, simplifying the transferring process while preserving color display functionality.
2Reliability
If redundant backup sub-pixels are added to replace defective ones, then display reliability is improved, but the number of LEDs required increases
Solution Approach 1:
The patent creates black sub-pixels using the same blue LED and color conversion member structure as functional sub-pixels. These black sub-pixels serve as backup/replacement elements that can be activated to replace defective colored sub-pixels, providing reliability without requiring separate redundant LED structures.
Solution Approach 2:
The patent uses parameter changes by controlling the activation state of sub-pixels. Black sub-pixels are configured to be inactive during normal operation but can be activated to replace defective colored sub-pixels, providing a dynamic reliability mechanism that doesn't permanently increase the active LED count.
3Manufacturing precision
If multiple transferring steps are used to place different LED types, then sub-pixel placement precision is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent achieves manufacturing efficiency by using a single LED type for all sub-pixel positions. This eliminates the need for multiple specialized transferring steps for different LED types, while placement precision is maintained through the standardized structure and integration with color conversion members.
Solution Approach 2:
The patent applies preliminary action by pre-configuring the color conversion members (quantum dots or phosphors) at their final positions before LED integration. This allows a single LED transferring step to suffice, as the color conversion layer is already in place to generate the required colors from the blue LEDs.
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 configuration minimizes the number of LEDs needed, reduces manufacturing costs, and simplifies the production process by allowing for efficient repair and alignment of sub-pixels, thereby improving yield and reducing greenhouse gas emissions.
Implementation Method 1
a color conversion member disposed on some light emitting diodes among the plurality of light emitting diodes
Implementation Method 2
a light shielding pattern which is disposed on the remaining light emitting diode of the plurality of light emitting diodes
Data Source
AI summary
A display device can include a substrate including a plurality of pixels; a plurality of light emitting diodes disposed in each of the plurality of pixels; a color conversion member disposed over at least two light emitting diodes among the plurality of light emitting diodes in one pixel among the plurality of pixels; and a light shielding pattern disposed over at least one light emitting diode among the plurality of light emitting diodes in the one pixel for forming a black sub pixel that does not emit light outside of the display device. Also, each of the plurality of pixels includes a first sub pixel, a second sub pixel, a third sub pixel, and one or more black sub pixels.