LED Transfer Alignment Keys for Display Panel Repair Precision
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Solution Overview
Problem
Current display device manufacturing methods face inefficiencies in repair transfer processes and alignment precision of light emitting diodes, leading to reduced productivity and yield.
Innovation Solution
A manufacturing method that utilizes a main alignment key on a wafer to transfer light emitting diodes onto a display panel, identifies defective LEDs, and employs a repair alignment key to accurately reposition and repair misplaced LEDs, improving the efficiency and precision of the repair process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional transfer process is used without separate repair alignment, then the manufacturing process is simpler, but the repair efficiency and productivity are reduced
Solution Approach 1:
The alignment key structure is segmented into two distinct components: a main alignment key for initial positioning and a repair alignment key for defect correction. This segmentation allows the repair process to be independently optimized without affecting the main transfer process, thereby improving repair efficiency while maintaining overall process clarity
Solution Approach 2:
The repair alignment key acts as an intermediary element that facilitates the repair process. It provides a dedicated reference structure that enables precise repositioning of defective LEDs without requiring complex realignment procedures, thus improving productivity while adding only minimal structural complexity
2Manufacturing precision
If conventional alignment methods are used, then the manufacturing process is simpler, but the alignment precision between light emitting diodes is reduced
Solution Approach 1:
The repair alignment key is prepared in advance on the wafer substrate, establishing a pre-defined reference framework before the transfer process begins. This preliminary action ensures that when defects are identified, the repair alignment can be immediately executed with high precision without requiring complex real-time calculations or adjustments
Solution Approach 2:
The repair alignment key replicates the positional reference information of the main alignment key, creating a redundant but precise reference system. This copying approach ensures that alignment precision is maintained during repair operations by providing an identical reference framework that can be independently utilized for corrective positioning
3Productivity
If defective LEDs are not specifically identified and repaired, then the manufacturing process is faster, but the yield and quality are reduced
Solution Approach 1:
The system incorporates a feedback mechanism where defective LEDs are identified through inspection, and this information is used to guide the repair process. The repair alignment key receives input about specific defect locations and automatically positions repair elements accordingly, enabling efficient targeted repair that improves yield without significant time loss
Solution Approach 2:
The repair process is designed to be self-directed through the repair alignment key, which automatically guides the placement of repair elements based on defect information. This self-service approach eliminates the need for manual intervention or complex external alignment procedures, thereby improving yield while minimizing the time required for defect correction
Data Source
AI summary
A manufacturing method of a display device may include: transferring light emitting diodes onto a display panel using an alignment key on a wafer; determining a defective light emitting diode which is missed or misplaced from a transferring position; and transferring at least one light emitting diode for repairing the defective light emitting diode onto the display panel using a repair alignment key. The method can improve a repair process efficiency. In a display device, at least one light emitting diode of a pixel may be in a second electrode area of an electrode area, and each of other light emitting diodes of the pixel may be disposed in a first electrode area of an electrode area of the pixel but not in a second electrode area of the electrode area. Some corresponding light emitting diodes of two pixels may be separated by a distance different from a pixel distance.