LED Display Pixel Repair Layout Without Photomask Redesign
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Solution Overview
Problem
Existing LED transfer technologies in display devices suffer from transposition errors, transfer failures, and LED failures, leading to non-functional pixels and increased repair costs.
Innovation Solution
A display device design incorporating a circuit substrate with dedicated repair regions for faulty LEDs, featuring insulation structures, top electrodes, and protective structures to facilitate easy replacement and integration of repair LEDs without requiring photomask redesign.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing LED transfer technology is used, then LEDs can be transferred to circuit substrate, but transposition errors and transfer failures occur causing pixel failures
Solution Approach 1:
The pixel region is divided into a first pixel region with a first bottom electrode and a second pixel region with a second bottom electrode. Each pixel region can be independently tested and repaired, allowing faulty LEDs to be identified and replaced without affecting other pixels, thus improving reliability while maintaining productivity
Solution Approach 2:
Repair regions are pre-designed within the pixel regions, and repair LEDs are prepared in advance. When a pixel fails, the repair process can immediately proceed by transferring a repair LED to the faulty location, eliminating the need for photomask redesign and reducing repair time and costs
2Reliability
If repair LEDs are transferred to replace faulty LEDs, then functional pixels are restored, but repair costs increase
Solution Approach 1:
The circuit substrate is designed with universal repair regions that can accommodate any faulty LED regardless of its original position. The same photomask design is used for both normal pixel fabrication and repair LED integration, eliminating the need for separate repair photomasks and reducing manufacturing costs
Solution Approach 2:
The repair LED structure is designed to be identical to the original LED structure, with the same electrode configurations and insulation structures. This allows repair LEDs to be transferred using the same processes as original LEDs, simplifying the repair process and reducing costs
3Manufacturing precision
If photomask redesign is performed for repair LEDs, then precise integration is achieved, but manufacturing complexity increases
Solution Approach 1:
The repair LED integration process is merged with the original LED fabrication process. The same photomask patterns are used for both placement regions and repair regions, and the same insulation structures and electrode configurations are applied. This unified approach maintains manufacturing precision while eliminating the need for separate repair photomask designs
Data Source
AI summary
A display device includes a circuit substrate, a first light-emitting diode (LED), a second LED, a repair LED, a first protective structure, and a second protective structure. The circuit substrate includes a first pixel region and a second pixel region. The first pixel region includes a first placement region and a first repair region, and the second pixel region includes a second placement region and a second repair region. The first LED and the second LED are respectively located on the first pixel region and the second pixel region. The repair LED is located on the first repair region. The first protective structure and the second protective structure are located on the first repair region and the second repair region respectively. The first protective structure is in contact with the repair LED.