Micro LED Pixel Redundancy Layout for Transfer Error Yield
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Solution Overview
Problem
The yield rate of micro LED-based display products is low due to transfer errors during the mounting of red, green, and blue micro LED chips on a substrate, which is a challenge in manufacturing large-sized displays.
Innovation Solution
A display apparatus is designed with a first pixel and a second pixel of the same color connected to different data lines, allowing them to be alternately driven in different periods, enhancing the yield rate by compensating for defective pixels through alternate driving methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If micro LED chips are mounted on a substrate through a transfer process, then the display can be manufactured with low power consumption and high brightness, but transfer errors occur frequently resulting in low product yield rate
Solution Approach 1:
The patent applies preliminary action by pre-assigning redundancy pixels to specific main pixels before the display operation begins. The redundancy pixel configuration is established in advance during the manufacturing stage, creating a predetermined compensation mechanism that activates only when transfer errors occur during mounting.
Solution Approach 2:
The patent implements beforehand cushioning by incorporating redundancy pixels as a buffer against transfer errors. These redundancy pixels serve as a protective reserve that compensates for potential defects, ensuring continuous display functionality even when some micro LED chips fail to transfer correctly to the substrate.
2Reliability
If multiple pixels of the same color are connected to different data lines and driven alternately, then the yield rate increases through defect compensation, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the display into unit pixels, where each unit pixel contains both a main pixel and a redundancy pixel of the same color. This segmentation allows independent control and compensation at the unit pixel level, isolating defects to specific segments while maintaining overall display functionality.
Solution Approach 2:
The patent utilizes parameter changes by dynamically switching the driving state between main pixels and redundancy pixels based on detected transfer errors. The system changes operational parameters (which pixel is actively driven) in response to error conditions, optimizing yield rate without permanently increasing structural complexity.
3Reliability
If redundancy pixels are allocated in unit pixels to compensate for transfer errors, then the yield rate is enhanced, but the manufacturing cost and process complexity increase
Solution Approach 1:
The patent applies merging by combining the main pixel and redundancy pixel into a single unit pixel structure. This integration allows both pixels to share common structural elements and control mechanisms, reducing the overall manufacturing complexity compared to implementing separate compensation systems for each pixel.
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 increases the yield rate of micro LED displays by effectively managing transfer errors and maintaining display quality without distortion, even when defective pixels are present.
Implementation Method 1
a first pixel including a light emitting device of a first color connected to a first data line and independently driven
Data Source
AI summary
A display apparatus includes a first pixel including a light emitting device of a first color connected to a first data line and independently driven and a second pixel including a light emitting device of the first color connected to a second data line adjacent to the first data line and independently driven, wherein the first pixel and the second pixel are included in a first unit pixel, and the first pixel and the second pixel are alternately on-driven in a first period and a succeeding second period.