μ-LED Pixel Redundancy With Separated Subpixels for Defect Compensation
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Solution Overview
Problem
Monolithic μ-displays face challenges due to the small size of light-generating components, leading to defects and variations in production, which can result in pixel failure, especially since individual defective pixels cannot be replaced in economically and procedurally sensible ways, affecting the quality and yield of μ-displays.
Innovation Solution
The proposed solution involves creating pixel elements with electrically separated and optically coupled subpixels, allowing for redundancy and defect compensation, where subpixels can be individually controlled and adjusted to maintain light emission even if one subpixel fails, using a subpixel separation element to prevent electrical crosstalk and ensure optical coupling, and employing a pixel element separation layer for electrical and optical separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If monolithic μ-displays are produced with small light-generating components, then the display resolution and integration are improved, but the production defects and pixel failure rate increase
Solution Approach 1:
The patent divides each pixel into multiple subpixels (e.g., red, green, blue subpixels) that can be independently controlled. This segmentation allows the display to maintain high resolution while providing redundancy, as individual subpixel failures do not result in complete pixel failure. The subpixels are electrically separated but optically coupled to achieve this balance between resolution and reliability.
Solution Approach 2:
The patent implements redundancy by providing multiple subpixels per pixel and preparing compensation mechanisms in advance. When a subpixel is detected as defective, the system can compensate by adjusting the brightness or operation of remaining subpixels before the defect becomes visually apparent, thereby cushioning against the impact of production defects on overall display quality.
2Ease of manufacture
If individual defective pixels cannot be replaced, then the manufacturing complexity and cost are reduced, but the quality and yield of μ-displays are affected
Solution Approach 1:
The patent enables the display to self-diagnose and self-compensate for defects through integrated control circuitry that can detect defective subpixels and automatically adjust the operation of remaining subpixels. This self-service capability eliminates the need for manual pixel replacement while maintaining display quality, as the system compensates for defects during normal operation.
Solution Approach 2:
The patent employs parameter changes in the form of brightness adjustment and operational timing modifications of subpixels to compensate for defects. By dynamically changing these parameters, the system can maintain perceived display quality even when individual subpixels fail, thereby preserving manufacturing simplicity while ensuring display quality.
3Manufacturing precision
If subpixels are electrically separated to prevent crosstalk, then the image quality is improved, but the device complexity increases
Solution Approach 1:
The patent introduces intermediate structures such as insulation layers and conductive patterns that act as mediators between adjacent subpixels. These intermediaries electrically isolate subpixels to prevent crosstalk while maintaining a manageable device structure. The intermediary elements are integrated into the existing pixel architecture, balancing image quality improvement with device complexity control.
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 enhances the yield and quality of μ-displays by allowing for the compensation of defective subpixels, reducing optical crosstalk, and maintaining image quality, while also extending the lifetime of functional subpixels through controlled operation.
Implementation Method 1
electrically separated and optically coupled subpixels, allowing for redundancy and defect compensation, where subpixels can be individually controlled and adjusted to maintain light emission even if one subpixel fails, using a subpixel separation element to prevent electrical crosstalk and ensure optical coupling
Implementation Method 2
employing a pixel element separation layer for electrical and optical separation
Data Source
AI summary
The invention relates to various aspects of a μ-LED or a μ-LED array for augmented reality or lighting applications, in particular in the automotive field. The μ-LED is characterized by particularly small dimensions in the range of a few μm.