Micro LED Repair via Selective Insulator Photoablation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of display devices using micro LEDs is challenging due to the small size of the LEDs, leading to defects and reduced yield, as defective LEDs cannot be properly repaired or reused.
Innovation Solution
A method for repairing display devices by detecting defective inorganic light emitting elements, removing the insulator around them using irradiation light, and then removing the defective elements, allowing for the replacement of alternative LEDs and reformation of insulators and conductors to restore functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If micro LEDs are mounted on a substrate to create display devices, then the display resolution and quality are improved, but the manufacturing difficulty increases and defects are generated due to the small size of the LEDs
Solution Approach 1:
The patent segments the repair process into distinct stages: detection of defective LEDs, removal of insulator material surrounding defective LEDs, and replacement with functional LEDs. This segmentation allows each step to be optimized independently, making the overall repair process more manageable and effective despite the small size of micro LEDs
Solution Approach 2:
The patent introduces an insulator removal step as an intermediary process between detecting defective LEDs and replacing them. By selectively removing the insulator material surrounding defective LEDs while preserving the insulator around functional LEDs, the patent enables precise targeting of defective elements without affecting surrounding components, thus facilitating repair despite manufacturing challenges
2Reliability
If defective LEDs are discarded and the display device is not used, then the reliability is maintained, but the yield is lowered
Solution Approach 1:
The patent enables recovery of defective display devices by selectively removing and replacing only the defective LED elements while preserving the functional LEDs and substrate. This approach transforms previously discarded defective devices into usable products, thereby improving yield while maintaining reliability through selective component replacement rather than complete device replacement
Solution Approach 2:
The patent changes the state of the insulator material from a protective covering to a removable target by applying specific irradiation conditions. This parameter change enables selective removal of insulator around defective LEDs without affecting the LEDs themselves or the insulator around functional LEDs, making the repair process feasible and improving overall device yield
3Ease of repair
If the insulator around defective LEDs is removed to enable repair, then the ease of repair is improved, but the complexity of the process increases
Solution Approach 1:
The patent replaces mechanical removal methods with optical irradiation for insulator removal. This substitution enables more precise and controlled removal of insulator material around defective LEDs, reducing the risk of damaging surrounding components and simplifying the overall repair process despite the added detection and irradiation steps
Solution Approach 2:
The patent employs a detection mechanism that automatically identifies defective LEDs based on their electrical or optical characteristics. This self-detection capability eliminates the need for manual inspection, reducing process complexity by providing automated guidance for the subsequent insulator removal and replacement steps
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 method enables the effective repair of display devices with defective LEDs, preventing yield loss and extending the usable life of the devices by allowing for the replacement of defective elements and reformation of necessary components.
Implementation Method 1
removing the insulator around the defective inorganic light emitting element while the defective inorganic light emitting element remains without being removed by irradiating the insulator around the defective inorganic light emitting element with irradiation light
Data Source
AI summary
A method for repairing a display device, the display device including a plurality of inorganic light emitting elements arranged in a matrix and an insulator arranged around the plurality of inorganic light emitting elements, the method comprising steps of: detecting a defective inorganic light emitting element as the inorganic light emitting element having a defect; removing the insulator around the defective inorganic light emitting element while the defective inorganic light emitting element remains without being removed by irradiating the insulator around the defective inorganic light emitting element with irradiation light; and removing the defective inorganic light emitting element after the insulator therearound has been removed.