Micro-LED Display Panel Layout for Layered Pixel Repair
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Solution Overview
Problem
The challenge of repairing LEDs after a large number of micro-LEDs are transferred simultaneously hinders the mass production of micro-LED displays.
Innovation Solution
A display panel design with main and auxiliary light-emitting units arranged in different layers, where auxiliary units correspond to non-working main units, allowing for effective repair by emitting light to replace non-functional units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a huge amount of LEDs are transferred all at once to achieve mass production, then productivity is improved, but the difficulty of repairing LEDs worsens
Solution Approach 1:
The patent applies preliminary action by pre-arranging auxiliary light-emitting units in specific positions before the transfer process. These auxiliary units are positioned in advance to correspond with potential defect locations, enabling immediate repair action without requiring post-transfer adjustments or complex realignment procedures
Solution Approach 2:
The patent introduces auxiliary light-emitting units as intermediary elements that mediate between the transferred LED array and the repair process. These auxiliary units serve as replaceable substitutes that can be activated or physically substituted to compensate for defective LEDs, simplifying the repair workflow while maintaining mass production efficiency
2Ease of repair
If auxiliary light-emitting units are added for repair purposes, then ease of repair is improved, but device complexity worsens
Solution Approach 1:
The patent resolves the complexity issue by transitioning from a two-dimensional planar arrangement to a three-dimensional stacked configuration. Auxiliary light-emitting units are positioned in different layers at different heights, allowing multiple repair-capable units to coexist without increasing lateral footprint or complicating the overall device layout
Solution Approach 2:
The patent applies nesting by arranging auxiliary light-emitting units within the vertical space already occupied by the main LED array. The auxiliary units are embedded in different layers, effectively nesting the repair functionality within the existing device structure without adding significant external complexity
Data Source
AI summary
The present application provides a display panel and a method of manufacturing a display panel. The display panel includes a plurality of light-emitting units, an encapsulation layer, an encapsulation substrate and a drive substrate. The light-emitting units are disposed between the encapsulation substrate and the drive substrate. The light-emitting units include main light-emitting units and auxiliary light-emitting units, which are arranged on different layers. The auxiliary light-emitting units are in one-to-one correspondence with at least some of the main light-emitting units. In a direction parallel to an extending direction of the drive substrate and/or the encapsulation substrate, a distance between a center of the main light-emitting unit and a center of the auxiliary light-emitting unit is not greater than twice of a length of a projection of the main light-emitting unit in the extending direction.