Bottom Emission MicroLED Display Repair via Light Confinement
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Solution Overview
Problem
MicroLED display panels face challenges in repairing defective microLEDs during manufacturing, as existing methods are destructive, time-consuming, and complicated, making it difficult to efficiently address abnormal pickups or defects post-bonding.
Innovation Solution
A bottom emission microLED display and repair method involving a transparent substrate, light guiding layers, and reflecting layers to guide and confine light, allowing for non-destructive replacement of defective microLEDs with repair microLEDs through a series of conductive and light guiding layer formations and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a destructive scheme is used to repair defective microLEDs, then the defective microLEDs can be removed, but the repair process becomes complicated and time-consuming
Solution Approach 1:
The patent divides the microLED array into individually addressable units with separate control electrodes. Each microLED can be independently activated or deactivated through its own selection electrode, allowing defective units to be isolated and repaired without affecting adjacent microLEDs. This segmentation enables localized repair operations rather than requiring complete panel disassembly or destructive procedures.
Solution Approach 2:
The patent incorporates test electrodes and testing circuitry during the initial manufacturing process, allowing defective microLEDs to be identified before final assembly. Additionally, the selection electrodes are pre-configured to enable individual microLED addressing, so that when defects are discovered, the repair process can immediately target specific units without requiring complex diagnostic procedures or destructive dissection of the panel structure.
2Ease of repair
If a destructive scheme is used to repair defective microLEDs, then the defective microLEDs can be removed, but the repair process becomes time-consuming
Solution Approach 1:
By segmenting the control structure into individual selection electrodes for each microLED, the patent enables targeted repair operations. Only the defective microLED and its immediate surrounding structures need to be accessed, rather than requiring complete panel disassembly. This significantly reduces repair time compared to destructive schemes that would require removing entire sections or using complex extraction procedures.
Solution Approach 2:
The patent introduces selection electrodes and control circuits as intermediary elements that facilitate non-destructive access to individual microLEDs. These intermediaries allow repair equipment to selectively activate or deactivate specific microLEDs and to replace defective units through controlled electrical connections rather than mechanical destruction, thereby streamlining the repair process and reducing time requirements.
3Illumination intensity
If light is allowed to leak upwards or sidewards from microLED, then the light output is not confined, but the display contrast and image quality deteriorate
Solution Approach 1:
The patent extracts and removes the light guiding layer from specific regions to create light blocking structures. By selectively removing material in the light guiding layer, the invention creates barriers that prevent light from leaking in unwanted directions while maintaining the overall light output from each microLED. This extraction approach allows precise control over light confinement without requiring complete structural redesign.
Solution Approach 2:
The patent applies different structural properties to different regions of the display panel. The light guiding layer is present in some areas to guide light and absent in other areas to block light, creating local variations in light confinement properties. This local quality approach allows each microLED region to have optimized light control characteristics, preventing lateral and upward light leakage that would otherwise degrade display contrast and image quality.
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 fast and convenient repair of microLED displays without destructive schemes, improving the efficiency and speed of the repair process while maintaining the integrity of the display panel.
Implementation Method 1
The light guiding layer surrounds the microLED to controllably guide light generated by the microLED towards the transparent substrate
Implementation Method 2
The reflecting layer is formed over the light guiding layer to reflect the light generated by the microLED downwards and to confine the light generated by the microLED to prevent the light from leaking upwards or sidewards
Data Source
AI summary
A bottom emission microLED display includes a microLED disposed above a transparent substrate; a light guiding layer surrounding the microLED to controllably guide light generated by the microLED towards the transparent substrate; and a reflecting layer formed over the light guiding layer to reflect the light generated by the microLED downwards and to confine the light generated by the microLED to prevent the light from leaking upwards or sidewards.