Micro LED Display Panel Repair via Laser Insulation Melting
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Solution Overview
Problem
Current display technologies face challenges in improving the success rate of repairing display panels, particularly for active matrix/micro light-emitting diode (AM Micro LED) displays, which require efficient methods to address issues like open circuits and short circuits in light-emitting diodes without compromising display performance.
Innovation Solution
The proposed solution involves a display panel configuration with multiple light-emitting diodes per sub-pixel unit, where a first light-emitting diode is preferentially activated, and a laser irradiation process is used to connect or disconnect second light-emitting diodes to electrodes through insulating layers, allowing for electrical reconfiguration to maintain display functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single light-emitting diode is used per sub-pixel unit, then the device structure is simple, but the repair success rate is low when the LED fails
Solution Approach 1:
The sub-pixel unit is segmented to include multiple light-emitting diodes (first LED and second LED) instead of a single LED. This segmentation allows the system to switch between different LEDs when one fails, thereby improving repair success rate while managing structural complexity through modular design
Solution Approach 2:
The patent changes the parameter of LED quantity from one to multiple per sub-pixel unit. This parameter change enables redundancy, where if the first LED fails, the second LED can be activated through laser irradiation to melt insulating layers and establish electrical connection, thus improving reliability
2Adaptability or versatility
If laser irradiation is used to connect or disconnect LEDs, then the repair flexibility is improved, but the manufacturing precision requirement increases
Solution Approach 1:
The patent introduces insulating layers as intermediaries between the LEDs and electrodes. These insulating layers can be selectively melted by laser irradiation to establish or disconnect electrical connections. The intermediary approach provides repair flexibility while the standardized insulating layer design helps manage the precision requirements of the laser process
3Adaptability or versatility
If multiple insulating layers are used to control LED connections, then the electrical reconfiguration capability is improved, but the device complexity increases
Solution Approach 1:
The insulating layers are pre-configured in specific positions between the LEDs and electrodes during manufacturing. This preliminary arrangement enables subsequent laser-based reconfiguration without requiring complex real-time control systems. The first and second insulating layers are strategically placed to allow selective melting and connection establishment
Solution Approach 2:
The patent extracts the connection control function from the electrical circuit design and places it in the insulating layer structure. By making the insulating layers removable through laser irradiation, the connection state can be changed without redesigning the entire electrical pathway, thus improving reconfiguration capability while managing complexity
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 enhances the success rate of repairing display panels by enabling efficient substitution of faulty diodes with functional ones, reducing repair costs and maintaining high display performance.
Implementation Method 1
using a laser irradiation process to melt and cut off the one of the first insulating layer and the second insulating layer
Implementation Method 2
using a laser irradiation process to melt and cut off the one of the first insulating layer and the second insulating layer
Implementation Method 3
a light-emitting structure including first light-emitting diodes and second light-emitting diodes
Data Source
AI summary
Display panel, repair method, and display device are provided. The display panel includes: a base substrate; an array substrate including driving thin film transistors (TFTs); first electrodes connected to the TFTs in a one-to-one correspondence; a light-emitting structure including first light-emitting diodes (LEDs) and second LEDs; a second electrode; and one of first and second insulating layers. In each sub-pixel unit, a first LED electrode and a third LED electrode of a first LED is connected to a corresponding first electrode and the second electrode, respectively; the first insulating layer is formed between a second LED electrode of a second LED and the corresponding first electrode, and a fourth LED electrode of the second LED is connected to the second electrode; and the second insulating layer is formed between the fourth LED electrode and the second electrode, and the second LED electrode is connected to the corresponding first electrode.