Micro LED Display Panels With Test Transistors for Anode Defect Detection

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Solution Overview

Problem

Micro LED display devices face reduced process efficiency due to defects in micro LEDs, which are difficult to detect using existing methods, particularly in the anode pads and connection wirings.

Innovation Solution

A display panel design incorporating test transistors connected to pixel circuits through pixel electrodes, allowing for defect detection by measuring current flow through these transistors when a voltage is applied, specifically identifying defects in anode pads and connection wirings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If existing detection methods are used for micro LED defects, then the detection process is simple, but the detection precision is insufficient especially for anode pads and connection wirings

Engineering Contradiction:
Improvedefect detection precisionVSAvoiddetection structure complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent incorporates test transistors and test electrodes into the pixel circuit structure before the actual product functionality is implemented. These test components are built in advance during the same manufacturing process, allowing defect detection to be performed prior to final assembly and application, thereby enabling early identification of defects in anode pads and connection wirings without requiring additional post-manufacturing inspection equipment.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent introduces test transistors as intermediary components that mediate between the pixel circuits and external detection equipment. These test transistors serve as access points that allow external devices to apply test voltages and measure current flow through the pixel electrodes and connection wirings, thereby enabling indirect detection of defects that would otherwise be inaccessible to direct measurement methods.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Manufacturing precision

If micro LEDs are mounted at dense intervals to increase display resolution, then the display quality is improved, but the process efficiency is greatly reduced due to defects

Engineering Contradiction:
Improvemicro LED arrangement precisionVSAvoidmanufacturing process efficiency
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The patent enables preliminary defect detection of pixel electrodes and connection wirings before micro LEDs are mounted. By using the built-in test transistors to perform electrical continuity and resistance measurements on the pixel electrodes and connection structures in advance, defects can be identified and marked for rework before the time-consuming micro LED mounting process begins, thereby preventing wasted effort on already-defective locations and improving overall manufacturing efficiency.

Inventive Principle:
Principle #10Preliminary action

3Reliability

If test transistors are added to detect defects in pixel electrodes, then the defect detection capability is improved, but the device structure becomes more complex

Engineering Contradiction:
Improvedefect detection capabilityVSAvoidpixel circuit structure complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the test transistor structure with the existing pixel circuit architecture by integrating test transistors alongside the drive transistors and utilizing shared components such as pixel electrodes and metal interconnect layers. This consolidation allows defect detection functionality to be added without requiring entirely separate test circuitry, thereby limiting the increase in structural complexity while still achieving reliable defect detection capability.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The test transistors are designed to serve multiple functions: they can detect defects in pixel electrodes, verify connection wiring integrity, and potentially characterize electrical properties of the pixel circuit components. This multi-functionality reduces the need for separate specialized test structures for each detection purpose, thereby achieving comprehensive defect detection capability without proportionally increasing device complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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

Enables effective detection of defects in anode pads and connection wirings, preventing issues with micro LED non-emission after bonding, thereby improving manufacturing efficiency and quality of micro LED display devices.

Implementation Method 1

detect whether at least one of the plurality of pixel electrodes is defective based on current flowing through one of the plurality of test transistors according to the voltage applied to the at least one of the plurality of pixel circuits

Methodology Applied
Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20250259577A1Display panel including test transistor and defect detection method for display panel
Publication Date: 2025.08.14 SAMSUNG ELECTRONICS CO LTD
  • US20250259577A1 patent drawing
  • US20250259577A1 patent drawing
  • US20250259577A1 patent drawing

AI summary

A display panel includes a plurality of pixel circuits configured to drive a plurality of inorganic light-emitting elements; a plurality of pixel electrodes configured to connect the plurality of inorganic light-emitting elements to the plurality of pixel circuits; a plurality of test transistors connected to the plurality of pixel circuits through the plurality of pixel electrodes; and at least one processor configured to: apply a voltage to at least one of the plurality of pixel circuits; and detect whether at least one of the plurality of pixel electrodes is defective based on current flowing through one of the plurality of test transistors according to the voltage applied to the at least one of the plurality of pixel circuits.