Micro-LED Pixel Repair Using Color-Converted Spare Sub-Pixels
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Solution Overview
Problem
Micro LED displays often suffer from defects such as open/short issues, transfer/integration/bonding defects, and substrate driver pixel defects, which can reduce yield and increase costs, especially when spare micro devices are used for repair.
Innovation Solution
The proposed solution involves a display system with a defect mapping block that maps data from defective sub-pixels to surrounding spare sub-pixels, allowing for the conversion of spare sub-pixels using color conversion or color filter materials to match the color of defective sub-pixels, thereby repairing the pixel circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If spare micro devices are used to replace defective micro devices, then yield is improved, but cost increases
Solution Approach 1:
The patent changes the functional parameter of existing sub-pixels by applying color conversion materials or filters. Instead of replacing defective sub-pixels with new spare micro devices, the invention modifies the emission characteristics of available sub-pixels through color conversion layers, quantum dots, or color filters to match the required color output, thereby avoiding the cost of additional spare devices while maintaining display functionality
Solution Approach 2:
The patent creates a functional copy of the required sub-pixel color output by converting existing sub-pixels. Rather than physically copying or replacing defective sub-pixels with identical spare devices, the invention uses color conversion mechanisms to replicate the desired color emission characteristics from available sub-pixels, achieving the same visual effect without additional material costs
2Manufacturing precision
If color conversion materials are applied to convert sub-pixel emission, then display quality is maintained, but manufacturing complexity increases
Solution Approach 1:
The patent segments the color conversion function into separate, independent layers (color conversion materials, quantum dots, color filters) that can be applied or integrated independently for each sub-pixel type. This segmentation allows for modular manufacturing processes where color conversion layers can be added separately from the base LED structure, enabling quality control at each stage without requiring complete re-manufacturing of complex integrated devices
Solution Approach 2:
The patent introduces color conversion materials and filters as intermediary elements between the LED emission source and the final display output. These intermediaries convert the wavelength emission from the LED to the desired color without requiring direct modification of the LED itself, simplifying the manufacturing process by decoupling the LED fabrication from the color conversion process
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 enables efficient repair of defective micro LED displays by increasing yield and reducing costs, as it allows for the effective reuse of spare sub-pixels without the need for replacing defective micro devices, thereby maintaining display quality and reducing material costs.
Implementation Method 1
converting the spare sub-pixel with a color conversion or color filter to create a color same as that of the defected sub-pixel
Implementation Method 2
applying a color filter material to at least one of the primary sub-pixels to convert the combined-wavelength emission into a different emission wavelength
Data Source
AI summary
What disclosed are structures and methods for repairing emissive display systems. Various repairing techniques embodiments in accordance with the structures and methods are provided to conquer and mitigate the defected pixels and to increase the yield and reduce the cost of emissive displays systems.