Micro-LED Pixel Repair Using Spare Sub-Pixel Color Conversion
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Solution Overview
Problem
Micro LED displays often suffer from defects such as open/short issues, transfer/integration/bonding defects, and substrate driver pixel defects, which can reduce yield and increase costs, especially when spare micro devices are used for repair.
Innovation Solution
The proposed solution involves a display system with a defect mapping block that maps data from defective sub-pixels to surrounding spare sub-pixels, allowing for effective repair of defective micro LED displays through color conversion or color filtering techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If spare micro devices are used to replace defective sub-pixels, then display yield is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses color conversion materials to transform the emission characteristics of spare sub-pixels, creating functional copies of the required color sub-pixels. Instead of physically replacing defective sub-pixels with identical spare devices, the system creates optical copies through wavelength conversion, thereby reducing the need for additional spare micro devices and lowering manufacturing costs while maintaining display yield.
Solution Approach 2:
The patent changes the emission wavelength parameter of spare sub-pixels by applying color conversion materials. By converting high-wavelength emission to low-wavelength emission or combining wavelengths, the system transforms spare sub-pixels into functional equivalents of defective sub-pixels, achieving repair without physical replacement and reducing overall manufacturing costs.
2Ease of repair
If color conversion materials are applied to convert wavelengths, then repair capability is improved, but device complexity increases
Solution Approach 1:
The patent extracts the color conversion function into separate material layers applied to sub-pixels, rather than integrating complex repair mechanisms into the display structure. This allows the repair functionality to be added independently through material deposition, simplifying the overall device architecture while enhancing repair capability.
Solution Approach 2:
The patent introduces color conversion materials as intermediary substances between the sub-pixel structure and the viewer. These materials act as mediators that transform the emission characteristics of existing sub-pixels, enabling repair functionality without direct modification of the sub-pixel hardware, thus maintaining device simplicity while improving repair capability.
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 enables efficient repair of defective micro LED displays, increasing yield and reducing costs by utilizing spare sub-pixels to replace defective ones, thereby maintaining display performance and quality.
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
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
Data Source
AI summary
What 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.