LED Sub-Pixel Scattering Layout for Repairable Display Panels
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Solution Overview
Problem
Existing display devices using LEDs face high manufacturing costs, light emission efficiency variations, and difficulty in reducing luminance variation with viewing angle, especially when repairing defective sub-pixels.
Innovation Solution
A display device design featuring a substrate with multiple reflective electrodes and distinct light scattering layers for different LEDs, allowing for efficient repair and improved light extraction efficiency by adjusting the shape and width of these layers based on LED type.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a light scattering layer is provided on all LEDs during manufacturing, then light extraction efficiency is improved, but manufacturing costs increase and repair complexity increases
Solution Approach 1:
The patent applies local quality by providing light scattering layers only on repair LEDs (second LEDs) rather than all LEDs. The light scattering layer is selectively formed on LEDs that require repair, using a mask pattern that covers only the repair LED regions. This approach improves light extraction efficiency where needed while avoiding unnecessary manufacturing steps for non-defective LEDs, thereby reducing overall manufacturing complexity and costs.
2Ease of repair
If repair LEDs are transferred during manufacturing process, then defective sub-pixels can be repaired, but manufacturing process complexity and costs increase
Solution Approach 1:
The patent implements preliminary action by preparing repair LEDs in advance and positioning them in designated regions before the defect detection and repair process. The repair LEDs are pre-formed on a separate substrate and then transferred to the display device substrate only when defects are detected. This preliminary preparation simplifies the repair process by having ready-to-use replacement components, reducing on-demand manufacturing complexity.
Solution Approach 2:
The repair process applies local quality by transferring and providing light scattering layers only to specific repair LEDs that correspond to defective sub-pixels, rather than processing all LEDs uniformly. This selective approach minimizes the impact on the overall manufacturing process while enabling targeted repairs.
3Reliability
If different light scattering layers are provided for different LED types, then light emission efficiency variation is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent addresses light emission efficiency consistency by providing different light scattering layer configurations for different LED types (first LEDs and second LEDs). The mask pattern is designed to selectively form light scattering layers with appropriate characteristics for each LED type and region. This localized optimization ensures that each LED receives the appropriate light scattering treatment, reducing efficiency variations while the mask alignment requirements are managed through the structured repair LED region design.
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
Reduces manufacturing costs by repairing defective LEDs only when necessary, minimizes light emission efficiency variations, and enhances light extraction efficiency while reducing power consumption.
Implementation Method 1
a first light scattering layer disposed on the plurality of first LEDs
Data Source
AI summary
A display device in one example includes a substrate in which a plurality of sub-pixels is defined, and a plurality of reflective electrodes disposed on the substrate. The display device further includes a plurality of first light emitting diodes (LEDs) disposed on the plurality of reflective electrodes in each of the plurality of sub-pixels, and a second LED disposed on the plurality of reflective electrodes in each of the plurality of sub-pixels and being different from the plurality of first LEDs. In addition, the display device includes a first light scattering layer disposed on the plurality of first LEDs, and a second light scattering layer disposed on the second LED and separated from the first light scattering layer.