Micro LED Electrode Slit Structure for Pre-Connection Light Testing
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Solution Overview
Problem
In the production of micro LED display panels, non-uniform adhesive overflow during mass transfer leads to short circuits and skewing of micro LED dies, making repair difficult and costly due to the need to remove the upper electrode block for light-testing.
Innovation Solution
The display panel design incorporates slits in electrode blocks to accommodate bonding blocks, increasing adhesion and reducing resistance, and allows light-testing through these slits without disassembling the electrode layer, enabling efficient detection and repair of micro LEDs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If light-testing is performed after upper electrode block is formed, then detection accuracy is improved, but repair difficulty increases and cost increases
Solution Approach 1:
The electrode structure is segmented into a lower electrode block and an upper electrode block. The lower electrode block contains light-transmitting regions that allow light to pass through for testing, while the upper electrode block can be removed for repair. This segmentation enables both accurate detection and easy repair by separating the testing function (lower block) from the protective function (upper block).
Solution Approach 2:
The lower electrode block with light-transmitting regions is prepared in advance before the upper electrode block is formed. This preliminary action allows light-testing to be performed early in the manufacturing process, before the upper electrode block is attached, making subsequent repair much easier if defects are detected.
2Productivity
If adhesive material is used for mass transfer, then manufacturing efficiency is improved, but non-uniform overflow causes short circuits and skewing
Solution Approach 1:
The lower electrode block acts as an intermediary structure between the adhesive material and the upper electrode block. It provides a stable base with light-transmitting regions that allows adhesive to be applied uniformly without causing short circuits or skewing, thereby maintaining both manufacturing efficiency and precision.
3Difficulty of detecting and measuring
If upper electrode block is removed for repair, then detection capability is improved, but manufacturing complexity increases and cost increases
Solution Approach 1:
The electrode structure is divided into removable upper electrode block and fixed lower electrode block. This segmentation allows the upper block to be removed for detection and repair without affecting the lower block that contains the light-transmitting regions, simplifying the overall manufacturing process despite the modular design.
Data Source
AI summary
A display panel of micro LEDs which provides a means of testing the installed micro LEDs for illumination qualities before final connections are made includes a transparent substrate, a plurality of electrode blocks on the transparent substrate, a plurality of conductive bonding blocks, and the micro LEDs. Each electrode block includes a slit allowing light to pass through. Each bonding block is on a surface of one electrode block away from the transparent substrate and is partially embedded in the slit of one corresponding electrode block. Each micro LED is fixed on one electrode block by a corresponding bonding block and is electrically connected with the electrode block. A method of manufacturing the display panel is further provided.