Micro-LED Pixel Repair Using Defect Mapping and Spare Subpixels

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Micro LED displays face defects such as device open/short issues and substrate driver pixel defects, leading to increased costs when using spare micro devices for repair, as existing repair methods can damage pixels and require additional micro devices, thereby increasing material costs.

Innovation Solution

The implementation of defect mapping techniques, color conversion, and spatial variation methods to redistribute the luminance contribution of defective subpixels to spare subpixels, allowing for effective repair without the need for additional micro devices, thereby reducing material costs and maintaining display quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If spare micro devices are used to replace defective subpixels, then display yield is improved, but material costs increase

Engineering Contradiction:

Improvedisplay yieldVSAvoidmaterial costs

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent creates a digital copy or map of the defective subpixel's characteristics and transfers this information to a spare subpixel. Instead of physically replacing the defective micro device, the system copies the functional characteristics and redistributes the luminance contribution through software-based defect mapping, eliminating the need for additional physical micro devices while maintaining display yield.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical/physical approach of swapping defective micro devices with a software-based defect mapping system. The luminance contribution redistribution is achieved through computational methods and data processing rather than physical manipulation of micro devices, substituting mechanical repair processes with electronic/software-based solutions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of repair

If existing repair methods are used, then defective pixels can be replaced, but additional micro devices are required increasing costs

Engineering Contradiction:

Improvedefect repair capabilityVSAvoidadditional micro devices

Core Design Contradiction:

Ease of repairVSQuantity of substance

Solution Approach 1:

The system creates a digital representation of the defective subpixel's characteristics and maps this information to spare subpixels. This copying approach allows the spare subpixels to assume the functional role of defective ones without requiring physical micro device replacements, thereby maintaining repair capability while eliminating the need for additional micro devices.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The spare subpixels are designed to be multi-functional, capable of serving both their original purpose and replacing defective subpixels through the defect mapping process. This universal design allows the same spare subpixels to fulfill multiple roles, eliminating the need for dedicated replacement micro devices.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If spare micro devices are used for repair, then yield is improved, but process complexity increases due to potential damage to pixels

Engineering Contradiction:

ImproveyieldVSAvoidrepair process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical repair processes with a software-based defect mapping system. Instead of physically handling and potentially damaging micro devices during repair, the system uses computational methods to redistribute luminance contributions, significantly simplifying the repair process while maintaining high yield.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The defect mapping system enables the display to self-diagnose and self-repair by automatically identifying defective subpixels and redistributing their luminance contributions to spare subpixels without requiring external intervention or complex manual repair processes.

Inventive Principle:

Principle #25Self-service

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

These methods enable efficient repair of micro LED displays by redistributing brightness or signal across spare subpixels, maintaining display performance while reducing material costs by minimizing the need for additional micro devices.

Implementation Method 1

converting the spare sub-pixel with a color conversion or color filter to create a color same as that of the defected sub-pixel

Methodology Applied

Scientific EffectColor conversion: Fluorescence

Implementation Method 2

applying a color filter material to at least one of the primary sub-pixels to convert the combined-wavelength emission into a different emission wavelength

Methodology Applied

Scientific EffectColor filtering: Filter (optical)

Data Source

PatentUS20240429223A1Repair techniques for micro-led devices and arrays

Publication Date: 2024.12.26 VUEREAL INC

AI summary

What is disclosed are structures and methods for repairing emissive display systems. Various repairing techniques embodiments in accordance with the structures and methods are provided to conquer and mitigate the defected pixels and to increase the yield and reduce the cost of emissive displays systems.