Micro LED Sub-Pixel Repair Layout for Precise Display Alignment
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Solution Overview
Problem
The challenge in micro LED display fabrication is the misplacement or failure of micro LEDs during the transfer process, necessitating a repair process for erroneous sub-pixels.
Innovation Solution
A display device design with a circuit substrate featuring placement and repair areas for LEDs, along with a bank structure and light-transmission structures, allowing for precise alignment and repair of misaligned or faulty LEDs, and a fabrication method that includes transfer, detection, and repair processes to ensure correct placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a repair process is implemented for misaligned micro LEDs, then display device performance is improved, but device complexity and fabrication cost increase
Solution Approach 1:
The sub-pixel area is segmented into a placement area and a repair area. The placement area receives micro LEDs during the transfer process, while the repair area is reserved for subsequent repair operations. This segmentation allows the repair process to be performed independently without affecting the overall display structure, thereby improving alignment accuracy while minimizing structural complexity.
Solution Approach 2:
The repair area is prepared in advance during the substrate fabrication process, before the transfer and repair operations are performed. This preliminary preparation includes forming the light-transmission structure in the repair area, which facilitates subsequent repair operations and reduces the complexity of the repair process.
2Ease of repair
If light-transmission structures are added for repair areas, then repair capability is improved, but fabrication cost increases
Solution Approach 1:
The light-transmission structure is formed only in the repair area, not across the entire substrate. This localized approach provides the necessary repair capability precisely where needed while minimizing the total quantity of materials used. The placement area does not require additional light-transmission structures since it receives micro LEDs during the transfer process.
3Manufacturing precision
If repair areas are designated for each sub-pixel, then alignment accuracy is improved, but manufacturing complexity increases
Solution Approach 1:
Each sub-pixel area is divided into a placement area and a repair area, with the repair area containing a light-transmission structure. This segmentation enables precise alignment by providing dedicated zones for different operations, while the regular, repeating pattern of this segmentation across the substrate maintains manufacturing simplicity through standardization.
Solution Approach 2:
The light-transmission structure in the repair area serves multiple functions: it facilitates the repair process by allowing light to pass through during repair operations, and it maintains the overall display structure. This multi-functionality reduces the need for additional specialized components, thereby simplifying the manufacturing process while improving alignment accuracy.
Data Source
AI summary
A display device includes a circuit substrate, light-emitting diodes, a bank structure, and light-transmission structures. The circuit substrate includes first sub-pixel areas, wherein each first sub-pixel area includes a placement area and a repair area. At least one corresponding light-emitting diode is disposed on at least one of the placement area and the repair area of each first sub-pixel area. The bank structure is located above the circuit substrate and has second sub-pixel areas. The first sub-pixel areas are overlapped with the second sub-pixel areas respectively. Each second sub-pixel area includes a preset opening and a repair opening. The preset openings are overlapped with the placement areas, and the repair openings are overlapped with the repair areas. The light-transmission structures are disposed in the second sub-pixel areas. Each light-transmission structure is disposed in one corresponding preset opening or in one corresponding repair opening.