Micro Lighting Device Redundant LED Repair
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Solution Overview
Problem
The manufacturing process of micro LEDs is complex and requires improvement in manufacturing yield due to the intricate nature of micro LED arrays, which are sensitive to defects and malfunctions.
Innovation Solution
A micro lighting device with a redundant luminescent device and a conductive material is introduced, where the redundant device can be electrically connected to replace a malfunctioning main luminescent device, using techniques like laser cutting and laser metal transfer to ensure continuous operation and improve yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a main luminescent device is used without redundancy, then device complexity is reduced, but reliability deteriorates due to inability to repair defective units
Solution Approach 1:
A redundant luminescent device is pre-configured on the substrate alongside the main luminescent device. The redundant device includes electrodes that are initially isolated but can be electrically connected through conductive material if the main device fails, enabling repair before the product reaches the customer.
Solution Approach 2:
The electrical connection state of the redundant luminescent device is changed from isolated to connected based on the operational status of the main device. Conductive material is added to change the electrical parameter from isolated to conductive, restoring functionality.
2Reliability
If redundant luminescent devices with electrical connection capabilities are added, then reliability is improved, but device complexity increases
Solution Approach 1:
The electrical connection function is extracted as a separate, optional feature. The redundant luminescent device exists with isolated electrodes by default, and the electrical connection is only established when needed through the addition of conductive material, keeping the base device simple.
Solution Approach 2:
Conductive material acts as an intermediary between the isolated electrodes of the redundant luminescent device and the existing electrode structure. This intermediary enables electrical connection without requiring complex integrated circuitry or switching mechanisms.
3Manufacturing precision
If complex manufacturing processes are used for micro LED arrays, then manufacturing precision is improved, but productivity deteriorates due to low yield
Solution Approach 1:
Multiple luminescent devices including redundant units are fabricated and transferred to the substrate in advance. This preliminary action ensures that repair capabilities are built into the structure before final testing and deployment, allowing defective units to be replaced without remanufacturing the entire array.
Solution Approach 2:
The electrical isolation parameter of the redundant device is changed from isolated to connected through the addition of conductive material. This simple parameter change enables functional restoration without requiring complex manufacturing interventions.
Data Source
AI summary
A micro lighting device includes a source line, a ground line, a main LED, and a redundant LED. The main LED includes a first electrode and a second electrode, and the redundant LED includes a third electrode and a fourth electrode. When the main LED is able to light up, the first electrode is electrically connected to the source line, the second electrode is electrically connected to the ground line, and at least one of the third electrode and the fourth electrode is electrically isolated from both the source line and the ground line. When the main LED is unable to light up, at least one of the first electrode and the second electrode is electrically isolated from both the source line and the ground line, the third electrode is electrically connected to the source line, and the fourth electrode is electrically connected to the ground line.