Micro-LED Pixel Repair Layer for Transfer Defect Compensation
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Solution Overview
Problem
Micro-LED displays face challenges in transferring millions of semiconductor light-emitting diodes due to difficulties in device transfer processes, such as pick & place and laser lift-off, which hinder the implementation of large-area displays.
Innovation Solution
A display device structure is developed with a substrate, semiconductor light-emitting diodes, a planarization layer, and a wiring electrode, incorporating a repair layer to replace defective diodes using light output from adjacent diodes, and a method to manufacture this structure by forming a repair layer over multiple pixel regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional transfer processes (pick & place, laser lift-off) are used for micro-LEDs, then device transfer can be performed, but the process complexity and difficulty increase significantly for large-area displays requiring millions of diodes
Solution Approach 1:
The patent uses a mask as a template to define pixel regions and repair regions, copying the desired pattern onto the substrate. This simplifies the transfer process by enabling batch processing of multiple diodes simultaneously rather than individual placement, thereby reducing process complexity while maintaining productivity
Solution Approach 2:
The substrate is divided into distinct pixel regions and repair regions using masks. This segmentation allows for selective processing of functional areas versus defective areas, enabling efficient transfer and repair operations without interfering with each other, thus reducing overall process complexity
2Reliability
If defective semiconductor light-emitting diodes are present in the display, then display quality deteriorates, but traditional repair methods are complex and time-consuming
Solution Approach 1:
The patent introduces a repair layer as an intermediary structure between the substrate and the defective diodes. This repair layer can be selectively formed in repair regions to replace defective diodes with light from adjacent pixels, providing a simplified repair mechanism that maintains display quality without complex repair procedures
Solution Approach 2:
The repair mechanism utilizes light output from adjacent functional pixels to replace defective pixels. The system essentially repairs itself by using its own operational components (adjacent diodes) to compensate for failures, eliminating the need for external complex repair processes and maintaining display quality efficiently
3Reliability
If a repair layer is formed to replace defective diodes using adjacent light output, then display quality is maintained, but the structural complexity increases
Solution Approach 1:
The repair layer is formed only in specific repair regions where defective diodes are located, not across the entire substrate. This localized approach maintains display quality in affected areas while minimizing the addition of structural complexity to the overall device, as the repair structure is applied selectively rather than universally
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 maintains display quality by simplifying post-processes and replacing defective diodes with adjacent light output, ensuring consistent performance.
Implementation Method 1
semiconductor light-emitting diodes disposed on the substrate... a second individual pixel region in which a repair layer is disposed to emit light output from the first individual pixel region adjacent thereto
Data Source
AI summary
The display device according to the present invention comprises: a substrate; semiconductor light-emitting diodes disposed on the substrate; a planarization layer formed so as to cover the semiconductor light-emitting diodes; and wire electrodes electrically connected to the semiconductor light-emitting diodes, wherein the substrate comprises individual pixel areas in which the semiconductor light-emitting diodes are disposed, and the individual pixel areas are each any one of first individual pixel areas, in which the semiconductor light-emitting diodes are disposed and which emit the light output by the semiconductor light-emitting diodes, and second individual pixel areas, in which a repair layer is disposed so as to emit the light output by an adjacent first individual pixel area.