Micro LED Subpixel Redundancy With Wavelength Conversion
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Solution Overview
Problem
The challenge in manufacturing micro LED image display devices is the low yield and high cost due to the increased number of elements required for high image quality, which complicates the inspection and mounting processes, making it difficult to achieve thin, high-luminance, wide viewing angle, high contrast, and low power consumption displays.
Innovation Solution
The solution involves an image display device with pixels comprising multiple subpixels, including a redundant subpixel that can emit the original color of a defective subpixel, using a wavelength conversion layer to adjust light emission colors, and a drive IC that stores the positions of defective subpixels to drive redundant subpixels accordingly, eliminating the need for pre-inspection of light-emitting elements and optimizing the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If micro LEDs are used to increase image quality, then luminance and viewing angle are improved, but manufacturing yield decreases due to multiple inspections
Solution Approach 1:
The patent applies preliminary action by pre-arranging redundant subpixels in the display panel before any inspection or mounting occurs. These redundant subpixels are positioned and configured in advance to replace defective ones, eliminating the need for post-inspection corrections and multiple inspection cycles, thereby maintaining high yield while achieving high luminance through micro LEDs
Solution Approach 2:
The patent implements discarding and recovering by identifying defective subpixels through inspection and then replacing them with pre-positioned redundant subpixels of the same color. This recovery process allows the display to maintain functionality and quality without requiring complete panel rejection, thus preserving manufacturing yield while utilizing micro LED technology for high luminance
2Reliability
If multiple inspections are performed to ensure quality, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent performs the action of arranging redundant subpixels preliminarily during the manufacturing process before final inspection. This preliminary configuration ensures that any defective subpixels can be replaced without requiring additional inspection cycles or costly rework, thereby maintaining high display quality while reducing overall manufacturing costs
Solution Approach 2:
The patent recovers from potential quality failures by replacing defective subpixels with redundant ones identified during a single inspection process. This approach maintains high reliability by ensuring all defects are corrected, while avoiding the cumulative costs of multiple inspection and rework cycles
3Manufacturing precision
If the number of elements increases for high image quality, then display resolution is improved, but device complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-arranging redundant subpixels throughout the display panel before mounting micro LEDs. This preliminary structure provides a built-in replacement system that simplifies the mounting process, as defective elements can be replaced without complex reconfiguration, thereby enabling high display resolution while managing device complexity
Solution Approach 2:
The patent recovers from the complexity of handling numerous micro LED elements by implementing a redundant subpixel system. When inspection identifies defective elements among the high-numbered components required for high resolution, the system automatically recovers by activating redundant subpixels, thereby simplifying the overall process and reducing inspection and mounting 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 increases the overall manufacturing yield by eliminating the need for pre-inspection of light-emitting elements and ensures good color reproducibility, achieving higher luminance and lower power consumption while maintaining cost competitiveness.
Implementation Method 1
a wavelength conversion layer provided over the light-emitting element to convert emission light emitted from the light-emitting element to converted light with the predetermined color
Data Source
AI summary
A method for manufacturing an image display device including providing a plurality of first subpixels and a second subpixel, where the plurality of first subpixels have a plurality of first light-emitting elements and are configured to emit red, green, and blue light, and the second subpixel has a second light-emitting element and being configured to emit blue light. A defective subpixel detection process includes turning on the plurality of first light-emitting elements, and acquiring data of position of at least one defective subpixel among the plurality of first subpixels, where the defective subpixel is supposed to emit predetermined light with a predetermined color. A wavelength conversion layer formation process includes providing a wavelength conversion layer over the second light-emitting element to convert emission light emitted from the second light-emitting element to the predetermined light with the predetermined color if the predetermined color is red or green.