Micro-LED Board Light-Blocking Structure for Laser Repair

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Solution Overview

Problem

Existing micro-LED display devices face challenges in efficiently managing defects and unintended light emission due to connection faults, which can lead to damage of wiring and uneven surfaces during laser-based repair processes.

Innovation Solution

A micro-LED board structure incorporating a substrate, wiring, a first insulating layer, a micro-LED, and a light-blocking layer, where the light-blocking layer is positioned between the insulating layer and the micro-LED, partially crossing the wiring below it, preventing laser light from reaching the wiring and reducing heat-induced separation at the interface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If laser light is used to repair defective micro-LEDs, then repair effectiveness is improved, but wiring damage occurs due to unintended light emission

Engineering Contradiction:

Improverepair effectivenessVSAvoidwiring damage

Core Design Contradiction:

Ease of repairVSObject-affected harmful factors

Solution Approach 1:

A light-blocking layer is introduced as an intermediary component between the micro-LED and the wiring layer. This layer selectively blocks laser light from reaching the wiring while allowing repair access to the micro-LED, thus preventing wiring damage during laser-based repair processes

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The light-blocking layer is designed with segmented openings that align with the positive and negative electrodes of the micro-LED. This segmentation allows laser light to pass through to reach defective areas for repair while blocking light from reaching adjacent wiring, achieving selective protection

Inventive Principle:

Principle #1Segmentation

2Ease of repair

If laser irradiation is applied to defective micro-LEDs, then repair capability is enhanced, but surface flatness deteriorates due to heat-induced separation

Engineering Contradiction:

Improverepair capabilityVSAvoidsurface flatness

Core Design Contradiction:

Ease of repairVSShape

Solution Approach 1:

The light-blocking layer serves as a protective barrier that absorbs and blocks laser energy from reaching the wiring and substrate interface. This beforehand protection prevents heat-induced separation and maintains surface flatness during laser repair operations

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If wiring is positioned directly below micro-LED for connection, then electrical connectivity is improved, but unintended light emission damages the wiring

Engineering Contradiction:

Improveelectrical connectivityVSAvoidunintended light emission

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The light-blocking layer acts as an intermediary structure positioned between the micro-LED and the wiring. It allows electrical connectivity to be maintained through the substrate while blocking harmful light emission from reaching the wiring, thus resolving the conflict between connectivity and protection

Inventive Principle:

Principle #24Intermediary (Mediator)

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 structure allows for effective repair of defective micro-LEDs without damaging the wiring, enhancing the longevity of the display device by preventing accidental breaking or cutting of the wiring and maintaining a flat surface, while also improving luminance and contrast by scattering or reflecting light effectively.

Implementation Method 1

a light-blocking layer, where the light-blocking layer is positioned between the insulating layer and the micro-LED, partially crossing the wiring below it, preventing laser light from reaching the wiring

Methodology Applied

Scientific EffectLight blocking: Absorption (EM radiation)

Implementation Method 2

improving luminance and contrast by scattering or reflecting light effectively

Methodology Applied

Scientific EffectLight scattering: Scattering

Implementation Method 3

improving luminance and contrast by scattering or reflecting light effectively

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 4

reducing heat-induced separation at the interface

Methodology Applied

Scientific EffectThermal protection: Thermal Insulation

Data Source

PatentUS12261260B2Micro-LED board and display device

Publication Date: 2025.03.25 KYOCERA CORP

AI summary

A micro-LED board includes a substrate, wiring, a first insulating layer, a micro-LED, and a light-blocking layer. The wiring, the first insulating layer, and the micro-LED are located on the substrate in an order of the wiring, the first insulating layer, and the micro-LED. The micro-LED overlaps the wiring. The light-blocking layer is located between the first insulating layer and the micro-LED, at least partially crosses a portion of the wiring directly below the micro-LED, and has an area that does not overlap a positive electrode and a negative electrode.