Micro LED Display Panel Electrode Design for Yield Improvement
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Solution Overview
Problem
The manufacturing process of micro LED display panels faces difficulties in detecting and repairing poor bonding between micro light-emitting-diodes and the receiving substrate, leading to increased product detection and repair challenges and reduced yield.
Innovation Solution
A micro light-emitting-diode display panel design with alternative first and second electrode contacts on a base substrate, allowing for immediate testing of micro light-emitting-diodes after transfer, and a manufacturing method that includes forming a top electrode before transfer to facilitate direct testing and replacement of non-functional diodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the top electrode is formed after transferring micro light-emitting-diodes to the receiving substrate, then the bonding process is completed, but the difficulty of detecting and measuring bonding quality increases and repair becomes difficult
Solution Approach 1:
The patent applies preliminary action by forming the top electrode on the micro light-emitting-diodes before transferring them to the receiving substrate. This allows the electrodes to be pre-assembled and tested independently, enabling easy detection of bonding quality through electrical connection tests before final substrate bonding occurs. If bonding issues are detected, the micro light-emitting-diodes can be replaced without complex rework.
2Ease of manufacture
If the top electrode is formed after transferring micro light-emitting-diodes to the receiving substrate, then the bonding process is completed, but the ease of repair deteriorates
Solution Approach 1:
By forming the top electrode before transfer, the patent enables preliminary assembly and testing of the micro light-emitting-diodes with their electrodes. This preliminary configuration allows defective units to be identified and replaced on the receiving substrate without requiring complex reassembly operations, significantly improving ease of repair.
3Difficulty of detecting and measuring
If the top electrode is formed before transferring micro light-emitting-diodes to the receiving substrate, then product detection and repair become easier, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the manufacturing process into distinct stages: first forming the top electrode on the micro light-emitting-diodes, then transferring them to the receiving substrate. This segmentation allows each stage to be optimized independently and simplifies quality control by enabling detection at the transfer stage before final assembly, actually reducing overall process complexity.
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 approach reduces the complexity of product detection and repair, improving the yield of micro LED display panels by enabling immediate testing and replacement of defective diodes, ensuring proper bonding and functionality.
Implementation Method 1
the micro light-emitting-diodes are lifted from the original substrate by a laser lift-off (LLO) technology
Data Source
AI summary
A micro light emitting-diode display panel and a manufacturing method thereof are provided. The first electrode contact and the second electrode contact are alternatively disposed on the base substrate of the micro light-emitting-diode display panel, and the first electrode contact and the second electrode contact are respectively connected with the bottom electrode and the connection electrode of the micro light-emitting-diode. The connection electrode is also connected with the top electrode of the micro light-emitting-diode, and the micro light-emitting-diodes can be immediately inspected after the micro-light-emitting-diode is transferred, to reduce the difficulty of detection and product repair, and to improve the product yield.