Micro-LED Panel Layout With Redundant Emitters for Defective Pixels
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Solution Overview
Problem
Micro-LED display devices face issues with defective pixels during manufacturing, leading to increased costs due to redundancy structures and potential damage to thin-film transistors during repair processes, along with challenges in reducing bezel area and implementing large screens.
Innovation Solution
A display device design where redundant light-emitting elements are disposed on a separate line substrate from the panel units, allowing for selective addition based on defect inspection, reducing the need for unnecessary redundant elements and minimizing damage to thin-film transistors, while also enabling a tiling arrangement that reduces bezel area and facilitates large screen implementation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a redundancy structure with two or more light-emitting elements per sub-pixel is implemented, then defective pixels are solved, but the cost of light-emitting elements increases significantly
Solution Approach 1:
The patent divides the display device into multiple panel units, each containing some light-emitting elements. This segmentation allows for selective replacement of only defective panel units rather than requiring redundancy in every sub-pixel, thereby reducing the overall quantity of light-emitting elements needed while maintaining reliability through modular replacement capability.
2Reliability
If repair process is used for defective light-emitting elements, then defective pixels are fixed, but thin-film transistors and stacked layers may be damaged
Solution Approach 1:
The patent incorporates test patterns during the manufacturing process to identify defective light-emitting elements before final assembly. This preliminary detection allows for selective replacement of only problematic panel units, avoiding the need for invasive repair processes that could damage thin-film transistors and stacked layers.
Solution Approach 2:
By segmenting the display into replaceable panel units with integrated light-emitting elements, the patent enables replacement of only defective modules without disturbing the delicate thin-film transistor structures that remain in the non-defective portions of the display.
3Area of stationary object
If panel units are coupled to line substrate in tiling manner, then bezel area is reduced, but manufacturing complexity increases
Solution Approach 1:
The line substrate is designed with universal coupling structures that can accommodate multiple panel units in various configurations. The standardized interface allows the same substrate design to serve multiple functions - supporting different numbers and arrangements of panel units - thereby reducing bezel area without proportionally increasing manufacturing complexity.
Data Source
AI summary
In a display device according to an embodiment of the present disclosure, a redundant light-emitting element is disposed on a line substrate separate from a panel unit in which the main light-emitting element is included, thereby reducing occurrence of a defective pixel due to a defective main light-emitting element.