Micro-LED Display Panel Repair Electrode Layout for Defective Pixels
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Solution Overview
Problem
Micro-LED display panels face challenges in achieving high definition and reliability due to the complexity of mounting and maintaining large numbers of micro-light-emitting diodes, particularly in ensuring proper electrical connections and addressing defective light-emitting elements during manufacturing.
Innovation Solution
The solution involves a display panel structure with a substrate, insulating layers, and pixels comprising drive transistors, conductive layers, pixel electrodes, and light-emitting elements, where a mounting electrode is used for defective light-emitting elements, allowing for electrical connection and repair through laser irradiation and additional element mounting, ensuring efficient light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a large number of micro-LEDs are mounted on the array substrate to achieve higher definition, then the display resolution is improved, but the complexity of mounting and maintaining electrical connections increases
Solution Approach 1:
The patent divides the array substrate into multiple substrate regions, each corresponding to a specific color (red, green, blue). This segmentation allows for organized mounting of micro-LEDs by color type, reducing the complexity of handling and mounting a large number of different micro-LEDs while maintaining high display resolution.
Solution Approach 2:
The patent forms conductive layers and mounting electrodes on the array substrate before mounting the micro-LEDs. This preliminary preparation of electrical connection structures simplifies the subsequent mounting process by having pre-positioned connection points, thereby reducing overall mounting complexity while enabling high-definition display.
2Ease of manufacture
If conventional mounting methods are used for micro-LEDs, then the manufacturing process is simple, but defective light-emitting elements cannot be repaired
Solution Approach 1:
The patent forms repair electrodes and conductive layers in advance on the array substrate before mounting micro-LEDs. These repair structures are prepared preliminarily to enable future repair operations without adding complexity to the initial manufacturing process, thus maintaining manufacturing simplicity while enabling defect repairability.
Solution Approach 2:
The patent introduces repair electrodes as intermediary structures that facilitate the replacement of defective micro-LEDs. These repair electrodes serve as mediators between the defective element and the replacement element, enabling repair operations while keeping the manufacturing process relatively simple.
3Ease of repair
If mounting electrodes are formed for all subpixels, then repair capability is improved, but device complexity increases
Solution Approach 1:
The patent forms repair electrodes and conductive layers locally at specific positions on the array substrate where micro-LEDs will be mounted, rather than uniformly across the entire substrate. This localized approach enables repair capability at critical positions while minimizing the overall complexity of the electrode structure.
Solution Approach 2:
The conductive layers formed on the array substrate serve multiple functions: they provide electrical connections for mounting electrodes during normal operation and also serve as repair electrodes for replacing defective micro-LEDs. This multi-functionality reduces the need for separate repair structures, thereby reducing device complexity while maintaining 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 the production of high-definition micro-LED displays with improved reliability by allowing for the identification and repair of defective elements, maintaining high definition and reducing manufacturing complexities.
Implementation Method 1
radiating laser light to the light-emitting element
Implementation Method 2
heating and melting the mounting electrode
Data Source
AI summary
According to one embodiment, a display panel includes a substrate, a first insulating layer, a second insulating layer, and pixels including subpixels of colors. Each of the subpixels includes a drive transistor, a conductive layer, a pixel electrode receiving a signal having a controlled current value from the drive transistor via the conductive layer, and a light-emitting element. Each of the pixels has a mounting electrode overlaid on the conductive layer in each of the subpixels. In a first pixel of the pixels, the mounting electrode is in an electrically floating state.