Repairing Short Circuit Defects in OLED Signal Wires
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Solution Overview
Problem
Short circuit defects in the signal wires of organic light emitting display apparatuses can occur during manufacturing, leading to defective pixels due to undesired particles, which existing technologies have not effectively addressed for repair.
Innovation Solution
A method involving the formation of an insulating layer to cover the affected signal wire, cutting both sides of the defect region, creating contact holes to expose the wire, and forming a repair metal layer connected via these holes, with a subsequent repair insulating layer to cover the area, ensuring the repair metal layer does not overlap with the original wire path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a short circuit defect occurs in signal wires during manufacturing, then defective pixels are created, but existing repair technologies cannot effectively address the problem
Solution Approach 1:
The signal wire is segmented by cutting it at both sides of the short circuit defect region, isolating the defective area. This segmentation allows the defective portion to be separated from the functional portions, enabling targeted repair without affecting the entire wire structure.
Solution Approach 2:
A repair wire is introduced as an intermediary element to bridge the gap created by cutting the original signal wire. This repair wire serves as a mediator to restore electrical connectivity between the separated segments, effectively bypassing the short circuit defect region.
2Reliability
If the signal wire is cut to isolate the defect, then the short circuit is prevented, but the wire continuity is disrupted
Solution Approach 1:
The repair wire acts as an intermediary conductor that restores continuity to the signal path. By introducing this intermediate element, electrical connectivity is maintained between the wire segments that were separated by cutting, thus preserving wire continuity while maintaining short circuit prevention.
Solution Approach 2:
The repair wire is merged with the existing wire structure by forming it to extend between the cut ends and connecting it to both segments. This merging restores the original wire continuity and creates a unified conductive path that bypasses the defective region.
3Reliability
If a repair structure is added to fix the short circuit, then the wire functionality is restored, but the device complexity increases
Solution Approach 1:
The repair is applied locally only at the specific location of the short circuit defect rather than redesigning the entire wire structure. The repair wire and associated layers are confined to the minimal area necessary to restore functionality, minimizing the increase in overall device complexity.
Solution Approach 2:
The repair wire and repair insulating layer are nested within the existing multi-layer structure of the display device. The repair components are integrated into the existing layer stack, with the repair insulating layer being disposed between the substrate and the repair wire, fitting within the available space without adding significant external complexity.
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 method effectively repairs short circuit defects by isolating the damaged area and rerouting the signal, preventing further short circuits and maintaining the display's integrity without compromising the existing wire structure.
Implementation Method 1
The cutting of the both sides of the region and the insulating layer may use laser
Data Source
AI summary
A method of repairing a defective pixel in a display apparatus that includes forming an insulating layer to cover the plurality of second signal wires, cutting both sides of a region of the corresponding second signal wire of the defective pixel and the insulating layer to form both sides of a cut region, forming contact holes adjacent to the both sides of the cut region, respectively, such that an upper portion of the corresponding second signal wire is exposed, forming a repair metal layer on the insulating layer to contact the contact holes and the second signal wire, and forming a repair insulating layer to cover the repair metal layer.