OLED Pixel Defect Repair via Connection Wire
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Solution Overview
Problem
Organic light emitting diode (OLED) displays often suffer from defective pixels that are not detected until manufacturing is complete, resulting in dark spots and reduced product yield, as existing methods do not effectively address pixel defects during the manufacturing process.
Innovation Solution
A method for manufacturing OLED displays that involves forming a connection wire between a defective and a normal pixel using materials like tungsten, chromium, or molybdenum to electrically connect them, and a second pixel defining layer to cover the connection wire, allowing the defective pixel to be driven by the normal pixel's signal, thereby repairing it.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing manufacturing methods are used, then manufacturing process is simple, but defective pixels are not detected until manufacturing is complete resulting in reduced product yield
Solution Approach 1:
The patent implements pixel defect detection and connection hole formation at intermediate stages during the manufacturing process, before final assembly is complete. This preliminary detection allows defective pixels to be identified and repaired early, preventing them from reaching final product inspection and thereby improving product yield without requiring complete manufacturing before detection.
Solution Approach 2:
The patent introduces connection holes as intermediary structures that enable electrical connection between adjacent pixels. These connection holes serve as mediators that allow signal transmission from normal pixels to defective pixels, enabling repair functionality without fundamentally changing the entire manufacturing process architecture.
2Reliability
If connection wire is formed to repair defective pixels, then defective pixels can be driven by normal pixel signals, but manufacturing process complexity increases
Solution Approach 1:
The patent merges the defect repair function with the existing pixel structure by forming connection holes that electrically connect defective pixels to adjacent normal pixels. This combining approach integrates the repair mechanism into the standard manufacturing flow without requiring entirely separate repair equipment or processes, thereby limiting the increase in manufacturing complexity.
Solution Approach 2:
The connection wire acts as an intermediary element that bridges the defective pixel and the normal pixel. This intermediary structure enables signal transmission without requiring complex repair equipment or fundamental changes to the manufacturing process, simply adding a conductive pathway between existing pixel structures.
3Manufacturing precision
If pixel defects are detected early, then defective pixels can be repaired reducing dark spots, but additional manufacturing steps are required
Solution Approach 1:
The patent performs pixel detection at an intermediate manufacturing stage before final assembly, allowing early identification of defective pixels. This preliminary detection enables repair actions to be taken during the manufacturing process itself rather than after completion, improving manufacturing precision while limiting the addition of post-manufacturing steps.
Solution Approach 2:
The patent extracts the detection and repair function from the final product inspection stage and moves it to an intermediate manufacturing stage. By taking out the defect detection step and performing it earlier in the process, the patent enables repair while minimizing the addition of overall manufacturing steps, as the detection is integrated into the existing manufacturing flow.
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 the repair of defective pixels during manufacturing, reducing the number of dark spots in the final product and improving yield, ensuring higher user satisfaction and productivity by preventing defective OLED displays from being discarded.
Implementation Method 1
a connection wire on the first pixel defining layer, the connection wire electrically connecting two adjacent pixels
Data Source
AI summary
An organic light emitting diode (OLED) display includes a substrate where a plurality of pixels are formed, a first pixel defining layer on the substrate, the first pixel defining layer dividing the plurality of pixels, a connection wire on the first pixel defining layer, the connection wire electrically connecting two adjacent pixels, and a second pixel defining layer on the first pixel defining layer, the second pixel defining layer covering the connection wire.