OLED Repair Unit for Pixel Yield Recovery
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Solution Overview
Problem
High-resolution and large-sized flat panel displays face significant production yield losses due to defective pixels, as entire substrates must be discarded when a single panel is defective, necessitating a repairable pixel structure and method for high-resolution and large-sized displays.
Innovation Solution
An organic light emitting device (OLED) display with a repair unit made of semiconductor material connecting the pixel circuit unit and OLED, allowing for laser-based repair by cutting the repair unit to convert white spot defects into dark spots, thereby restoring functionality without discarding the entire substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the resolution and size of flat panel display are increased, then the image quality and viewing area are improved, but the production yield deteriorates due to higher likelihood of defective pixels
Solution Approach 1:
The patent introduces a repair unit that can be individually removed or deactivated, segmenting the display into functional and non-functional regions. This allows defective pixels to be isolated without affecting the entire substrate, thereby maintaining high production yield while enabling high-resolution displays with larger pixel counts.
Solution Approach 2:
The patent enables recovery of defective substrates by allowing selective removal or deactivation of repair units corresponding to defective pixels. Instead of discarding entire substrates with defects, the system recovers functionality by isolating defective regions, thus improving production yield while maintaining high display resolution.
2Reliability
If a defective pixel is found in large-sized display, then the display quality is compromised, but discarding the entire substrate causes significant economic loss
Solution Approach 1:
The patent extracts the repair unit as a separate, removable component that can be selectively removed or deactivated corresponding to defective pixels. This extraction allows the defective region to be isolated without affecting the rest of the display, maintaining display quality while avoiding the economic loss of discarding entire substrates.
Solution Approach 2:
The patent enables recovery of valuable substrate material by allowing selective removal of only the defective repair unit rather than discarding the entire substrate. This recovers the majority of the substrate for reuse or repair, significantly reducing economic loss while maintaining display quality through defect isolation.
3Ease of repair
If a repair unit is added to enable pixel repair, then the ease of repair is improved, but the device complexity increases
Solution Approach 1:
The patent merges the repair unit with the existing pixel circuit structure, integrating repair functionality into the standard pixel design. The repair unit shares common elements with functional pixels (such as the OLED and circuit components), reducing overall device complexity while enabling ease of repair through selective removal or deactivation of the repair unit.
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 efficient repair of defective pixels, reducing production yield loss and economic costs by allowing for the repair of individual defective pixels within a larger OLED display, maintaining display integrity and functionality.
Implementation Method 1
applying a laser beam onto the repair unit of the pixel which has the white spot defect
Implementation Method 2
The applying of the laser beam may cause cutting the repair unit to change the pixel to a dark spot
Data Source
AI summary
Provided is an organic light emitting display including a pixel circuit unit prepared over a substrate and comprising a plurality of thin film transistors (TFTs), and an organic light emitting device or diode (OLED) electrically connected to the pixel circuit unit. The pixel circuit unit and the OLED are connected through a repair unit comprising a semiconductor material, in order to facilitate easy repair.