Micro-LED Panel Molding Structure for Post-Molding Pixel Repair
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Solution Overview
Problem
Existing display panels with micro-LEDs face challenges in repairing defective pixels after the molding process, leading to costly replacements due to the difficulty in accessing and replacing covered micro-LEDs.
Innovation Solution
A method involving partial removal of the molding member, planarization of bonding portions, and replacement of defective pixels with new ones, followed by application of a molding agent and film to ensure a flush surface and improved light transmittance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a molding member covers the micro LEDs to protect them and improve contrast ratio, then protection and contrast are improved, but repairability of defective pixels deteriorates
Solution Approach 1:
The molding member is divided into a first molding member covering most micro LEDs and a second molding member with higher light transmittance covering specific regions. This segmentation allows selective access to certain micro LEDs for repair while maintaining protection and contrast for others, resolving the contradiction between overall protection and localized repairability.
Solution Approach 2:
The second molding member is designed with different properties (higher light transmittance) than the first molding member to create a localized repair access region. This local quality change enables repair operations in specific areas without compromising the protective function of the overall molding structure.
2Illumination intensity
If a molding member covers the micro LEDs to improve contrast ratio, then contrast ratio is improved, but light transmittance to defective pixels deteriorates
Solution Approach 1:
The second molding member covering the repair region has higher light transmittance compared to the first molding member. This local quality differentiation ensures sufficient light reaches the micro LEDs in the repair region while the first molding member maintains high contrast ratio for the majority of the display panel.
3Productivity
If the molding process is completed to finalize the display panel, then manufacturing efficiency is improved, but the ability to repair defective pixels deteriorates
Solution Approach 1:
The molding process is designed to leave the second molding member with higher transmittance in place before final assembly, creating a preliminary repair access pathway. This preliminary action enables future repair operations without requiring complete disassembly, maintaining manufacturing efficiency while preserving repairability.
4Ease of repair
If the second molding member has higher light transmittance to enable repair access, then repairability is improved, but contrast ratio deteriorates
Solution Approach 1:
The molding member is segmented into two functional zones: the first molding member with standard properties for high contrast ratio, and the second molding member with higher transmittance for repair access. This segmentation localizes the contrast impact to only the repair region while preserving overall display contrast.
Solution Approach 2:
The second molding member's higher transmittance property is localized to the repair region, creating a focused access point that does not significantly impact the overall contrast ratio of the display panel. The first molding member maintains standard contrast properties for the majority of pixels.
Data Source
AI summary
A method of repairing a display panel and a repaired display panel are provided. The display panel includes a panel substrate, a plurality of micro LEDs arranged on the panel substrate, and a molding member covering the plurality of micro LEDs. The molding member includes a first molding member and a second molding member disposed in a region surrounded by the first molding member. The second molding member has a composition or a shape different from that of the first molding member, and the second molding member surrounds at least one side surface of the plurality of micro LEDs.